M-1002 Section C-III Specifications For Tank Cars 2007

10/2007
Association of American Railroads

SAFETY AND OPERATIONS
MANUAL OF STANDARDS
AND
RECOMMENDED PRACTICES
SECTION C-III
SPECIFICATIONS FOR TANK CARS
ISSUE OF OCTOBER 2007
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

50 F Street, N.W., Washington, D.C. 20001-1564
© Copyright Association of American Railroads
Printed in U.S.A.
10/2007
Copyright © 2007 by the Association of American Railroads (AAR)

Safety and Operations
50 F Street NW
Washington, D.C. 20001-1564
All rights reserved, including the right to reproduce this book in any form. It is the AAR’s intention that this publica-
tion 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 pur-
chaser 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 net-
work 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
Copies of the various sections of this manual can be obtained as follows:
ORDERS FOR Publications Department

PUBLICATIONS Transportation Technology Center, Inc.
P.O. Box 11130
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Email: pubs@ttci.aar.com
Phone: Toll-free 877-999-8824, Direct 719-584-0538
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CIRCULAR Subscriptions to Circular Letters of the AAR Safety and Operations’ Technical Services are available in
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SUBSCRIPTIONS at least monthly and include industry letter ballots and results, arbitration decisions, notification of rules
and standards revisions, industry early warning and maintenance advisories, and other information related
to mechanical rules and standards. Annual subscriptions commence on July 1 and terminate on June 30
of each year.
For ordering information, contact the following:
Phone: Toll-free 877-999-8824, Direct 719-584-0538
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Email: pubs@ttci.aar.com
AAR Web page: http://www.aar.org
TTCI Web page: http://www.ttci.aar.com
MSRP-A1 MSRP-A1 is an inclusive index of all MSRP specifications, standards, and recommended practices. It is
INDEX available online at http://www.aar.com/aar_standards-publications.htm 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 .
TECHNICAL For technical questions regarding this manual, contact the following:
QUESTIONS Executive Director, Tank Car Safety
50 F Street NW
Washington, DC 20001-1564
Email: kdorsey@aar.org
Phone: 202-639-2262
Fax: 202-639-2356
10/2007 C-III–i
THIS PAGE LEFT BLANK INTENTIONALLY
C-III–ii 10/2007
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 author-
ity 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 require-
ments, 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: Acceptability of Tank Containers and Tank Trailers
• 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 Reg-
ulations 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 un-
bound 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.
USER’S GUIDE
Section C, Part III, consists of the following:
• Preface: A listing of the subjects covered in the individual volumes making up this man-
ual. This preface is part of each section.
• Table of Contents: Identification of the 6 chapters and 14 appendices in numerical order.
• Specification M-1002: The body of this volume is a single specification setting forth man-
datory requirements for virtually all phases of tank car design.
• Recommended Practice RP-263: Appendix U, “Maintenance Program Development
(RP-263),” is included in M-1002 as a recommended practice.
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 Con-
struction of Freight Cars. Other sections containing pertinent information are the following:
• Section B—Couplers and Freight Car Draft Components
• Section D—Trucks and Truck Details
• Section E—Brakes and Brake Equipment
• Section G—Wheels and Axles
• Section H—Journal 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 October 2007 issue of M-1002 includes Tank Car Committee actions through the January 2007
meeting.
10/2007 C-III–iii
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 Di-
vision 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 A—Table of Contents, Alphabetical and Numerical Index of Sections B through S
inclusive (this is available as a free download at http://www.aar.com/aar_standards-publications.htm)
• Section B—Couplers and Freight Car Draft Components (100 Series)
• Section C—Car Construction—Fundamentals and Details (200 and 2000 Series)
• Section C, Part II—Design, Fabrication, and Construction of Freight Cars, M-1001
• Section C, Part III—Specifications for Tank Cars, M-1002
• Section D—Trucks and Truck Details (300 and 3000 Series)
• Section E—Brakes and Brake Equipment (300, 400, and 4000 Series)
• Section E, Part II—Electronically Controlled Brake Systems
• Section F—Vacant
• Section G—Wheels and Axles (600 Series)
• Section G, Part II—Wheel and Axle (Shop) Manual (600 Series)
• Section H—Journal Bearings and Lubrication (700 Series)
• Section H, Part II—Roller Bearing (Shop) Manual (700 Series)
• Section H, Part III—Lubrication (Shop) Manual (700 Series)
• Section I—Intermodal Equipment Manual
• Section J—Specification for Quality Assurance, M-1003
• Section K—Railway Electronics (5700 Series)
• Section K, Part II—Railway Electronics (5800 Series)
• Section K, Part III—Railway Electronics (5900 Series)
• Section L—Lettering and Marking of Cars (900 Series)
• Section M—Locomotives and Locomotive Interchange Equipment
• Section N—Multi-Level Manual
• Section S—Casting Details
• Section S, Part II—Truck Details and Casting Codes
• Section S, Part III—Coupler and Yoke Details
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). The prefix “S” or “RP” will be
followed by a three- or four-digit number. The first digit, 0 through 9, indicates the section in which
the standard or recommended practice can be found, as shown in parentheses above.
MEMBERS OF THE AAR TANK CAR COMMITTEE

A current mailing list, for use in filing applications, may be obtained from the Association of Amer-
ican Railroads, 50 F Street NW, Washington, D.C. 20001-1564, attention Mr. K.B. Dorsey (tele-
phone 202-639-2262).
C-III–iv 10/2007
SECTION C-III
TABLE OF CONTENTS
Chapter Subject Page
1 Introductions, Approvals, and Reports C-III–1
2 AAR Special Requirements for DOT Tank Cars C-III–45
3 Specifications for AAR Tank Car Tanks C-III–59
4 Acceptability of Tank Containers and Tank Trailers C-III–75
5 General Design and Test Requirements C-III–81
6 Car Structure Design and Test Requirements C-III–93
Appendix Subject Page

A Tank Car Valves and Fittings C-III–101
B Certification and Registration of Facilities C-III–133
C Marking of Tank Cars C-III–153
D Retest and Qualification Requirements C-III–171
E Design Details C-III–213
H Basic Philosophy and Principles for the Metrication of the AAR C-III–311
L Interior Cleaning, Lining, and Coating C-III–319
M Specifications for Materials C-III–327
P Tank Car Committee Procedures C-III–347
R Repair, Alteration, and Conversion to Tank Car Tanks C-III–349
S Loading Appurtenances for Tank Car C-III–393
T Nondestructive Examination C-III–397
U Maintenance Program Development (RP-263) C-III–431
W Welding of Tank Car Tanks C-III–445
X DOT Regulations C-III–525
Y Selected AAR Circular Letters C-III–565
See back of book for AAR forms for reproduction by the proponents.
10/2007 C-III–v
C-III–vi 10/2007
10/2007
M-1002 CHAPTER 1
CHAPTER 1
INTRODUCTIONS, APPROVALS, AND REPORTS
CONTENTS
Paragraph Subject Page

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–3
1.1.1 Historical Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–3
1.1.2 Legal Authority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–3
1.1.3 List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–4
1.2 Abbreviations and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–10
1.2.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–10
1.2.2 Definitions, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–11
1.2.3 Tank Car Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–12
1.3 General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–16
1.3.1 Car Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–16
1.3.2 DOT Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–16
1.3.3 AAR Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–16
1.3.4 Safety Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–16
1.3.5 Interchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–16
1.3.6 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–17
1.3.7 Editions of Referenced Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–17
1.3.8 Calibration and Capacity Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–17
1.3.9 Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–18
1.3.10 Age Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–18
1.3.11 Head Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–18
1.3.12 Rebuilt Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–18
1.3.13 Commodity Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–18
1.3.14 Reporting Marks and Car Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–18
1.3.15 Documentation at the Sale of Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–18
1.3.16 Requirements for Tank Cars with Gross Rail Load Over 263,000 lb to 286,000 lb, Inclusive. . . . . . C-III–19
1.3.17 Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–20
1.4 Procedures for Securing Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–20
1.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–20
1.4.2 Approval of Precedent and Nonprecedent Tank Car Designs (Form AAR 4-2) . . . . . . . . . . . . . . . . C-III–20
1.4.3 Application Form AAR 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–24
Fig. 1.1 Form AAR 4-2 Application for Approval and Certificate of Construction. . . . . . . . . . . . . . . . . . . . . . C-III–28
Fig. 1.2 Form AAR 4-2.1 Supplementary page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–29
1.4.4 Certificate of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–30
1.4.5 Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–30
Fig. 1.3 Form AAR 4-3 Application for Approval of Pressure Relief Device . . . . . . . . . . . . . . . . . . . . . . . . . C-III–32
1.4.6 Valves and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–33
10/2007 C-III [M-1002] 1

10/2007
CHAPTER 1 M-1002

Fig. 1.4 Form AAR 4-5 Application for Approval of Valves and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–35
Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Valves and Fittings. . . . . . . . . . . . . . . . . . . C-III–37
1.4.7 Renewal of Approval for Valves and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–36
Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–40
1.4.8 AAR Service Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–38
Fig. 1.7 Form AAR 4-6 Final Product Test and Inspection Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–42
1.4.9 Final Product Test and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–41
1.4.10 Certified Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–43
1.5 Certification of Independent Third Parties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–44
1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–44
1.5.2 Requirements and Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–44
1.5.3 Procedures for Obtaining Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–44
C-III [M-1002] 2 10/2007

10/2007
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’ Associa-
tion 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 transpor-
tation 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 Regula-
tions. 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 Materi-
als Regulations currently include Title 49, Code of Federal Regulations, Parts 100–199.
The specifications in this volume also prescribe AAR specifications for tank car tanks for the trans-
portation of nonhazardous and DOT low-hazard commodities.
This issue of the AAR Specifications for Tank Cars dated October 2007 supersedes the issue dated
October 1, 2003.
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 in paper and CD-ROM versions as AAR Bureau of
Explosives Tariff No. BOE-6000 by Charles L. Keller, Agent (phone 410-974-4265; orders 412-741-
1096).
DOT’s hazardous materials regulations are available for viewing or download from their Web site
at http://www.hazmat.dot.gov.
In Canada, Transport Canada, Transport Dangerous Goods Directorate, Regulatory Affairs
Branch, prepares and administers the regulations for transport of dangerous commodities. Cur-
rent issues of the regulations and guide are published by ICC International Compliance Centre,
Ltd., 205 Matheson Boulevard East, Mississauga, Ontario, Canada L4Z 1X8. The Transportation
of Dangerous Goods Regulations and Act are available for viewing or download from Transport
Canada’s Web site at http://www.tc.gc.ca.
1.1.2 Legal Authority
The Department of Transportation’s hazardous materials regulations are issued under the author-
ity 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.
10/2007 C-III [M-1002] 3

10/2007
CHAPTER 1 M-1002
1.1.3 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 5)
(See end of table for footnotes)
Originally Latest Obsolete for New Operational
Specification
a/ Approved Revision Construction Status
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-211A100W6 11-10-71 — — —
C-III [M-1002] 4 10/2007

10/2007
M-1002 CHAPTER 1

Specification
by AAR b/ b/ c/
AAR-211A100ALW1 11-10-66 11-10-71 — —

ICC-103 7-1-27 — 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/
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/
10/2007 C-III [M-1002] 5

10/2007
CHAPTER 1 M-1002

Specification
by AAR b/ b/ c/
DOT-105J500W 8-31-81 — — i/
DOT-105J600W 8-31-81 — — i/
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/
ICC-111A60ALW 7-19-59 12-19-64 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 — —
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10/2007
M-1002 CHAPTER 1

Specification
by AAR b/ b/ c/
ICC-111A100ALW 5-22-65 — 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-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/
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-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-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/
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/
10/2007 C-III [M-1002] 7

10/2007
CHAPTER 1 M-1002

Specification
by AAR b/ b/ c/
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 — — —
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 — — —
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 contin-
ued 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 1.2.3.1.
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 protec-
tive devices required by DOT 173.31. See paragraph 1.2.3.1.
l/ See 174.83 for special handling requirements.
m/ Existing cars restenciled DOT-120A500W, new construction not authorized.
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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 A240–304, –304L, or TC133
Insulation Optional 179.400–4
Burst pressure, psi (kPa) 350 (2413) 440 (3034) 300 (2068)
Tank construction Fusion-welded Fusion-welded. Impact tests
req’d. (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
10/2007 C-III [M-1002] 9

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CHAPTER 1 M-1002
1.2 Abbreviations and Definitions

1.2.1 Abbreviations
The following abbreviations apply in these specifications:
Table 1.3 Abbreviations
AAR Association of American Railroads
AAR Specification M-1001 The Specifications for Design, Fabrication, and Construction of
Freight Cars, published by the AAR
AISI American Iron and Steel Institute
ANSI American National Standards Institute
Approved Approved by the AAR Tank Car Committee
ASME American Society of Mechanical Engineers
ASNT American Society for Nondestructive Testing
ASTM American Society for Testing and Materials
AWS American Welding Society
°C degrees Celsius
CFR Code of Federal Regulations
CGSB Canadian General Standards Board
Committee AAR Tank Car Committee
CSA Canadian Standards Association
Commission Interstate Commerce Commission
Director Executive Director-Tank Car Safety (AAR)
DOT or Department Department of Transportation
°F degrees Fahrenheit
ICC Interstate Commerce Commission
kPa kilopascals gauge
kPa (abs.) kilopascals absolute
NGT National Gas Taper Thread
NPT American Standard Taper Pipe Thread
psi pounds per square inch gauge
psia pounds per square inch absolute
Definitions in DOT 171, DOT 173, and DOT 179.2 also apply.
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M-1002 CHAPTER 1
1.2.2 Definitions, General
Table 1.4 General definitions

Built date (tank car) The date (month and year) that the completed car is shipped from
the car builder’s facility. Tank cars shipped to lining applicator,
whether or not returned to the car builder after lining, are consid-
ered “built” as of the first departure from the car builder’s facility
Capacity (tank car) Its shell-full volume.
Certified car A stub sill, nonpressure, nonexterior coiled car built prior to July
1, 1974, and meeting the requirements of paragraph 1.4.10.
Class (tank car) A general designation usually including several specifications
(e.g., “Class DOT-111A” 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.
Connections Consists of nozzles, manways, flanges, and other pressure-retain-
ing attachments welded directly to a tank to allow access to its
interior.
Shell-full For cars constructed after May 1, 2001, the liquid volume at the
transition point at which air or vapor becomes entrapped in a
location that is not in direct communication with all top fittings.
See Fig. E14 for examples.
For cars constructed before May 1, 2001, compliance with this def-
inition is optional.
This shell-full volume is not to be used when calculating the filling
density of the lading. A tank is calibrated to accurately measure
its capacity. A tank is gauged to determine the quantity of liquid
loaded into it. Shell-full stamping on tank car heads is the net vol-
ume with allowance for tank internals.
Specification (tank car) The specific designation within a class (e.g., “Specification DOT-
111A100W2”).
Stub sill tank car A stub sill tank car (or a tank car without continuous center sill)
has draft sills at each end of the tank instead of a continuous cen-
ter sill and utilizes its tank as a part of the car structure.
Tank Consists of a shell, heads, and sump, together with the welds join-
ing them. As used in these specifications, “tank” means tank car
tank. The head of a tank is one of the end closures.
Tank test date (initial The date of test of the tank on the completed car must be the same
stenciled) year as the built 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.
Type (tank car) Designates the approving authority (e.g., AAR, ARA, ICC, DOT, or
USG). Preferred usage is, for example, “DOT tank cars.”
10/2007 C-III [M-1002] 11

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CHAPTER 1 M-1002
1.2.3 Tank Car Definitions

Tank cars currently in service are of three types: DOT, AAR, and ICC. See paragraph 1.1.3 for
specifications in effect for new construction.
1.2.3.1 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 suf-
fix 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 ser-
vices or requiring special fittings or materials of construction are designated by letters interposed
for the asterisk.
Table 1.5 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 1.6 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
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 1.7 Class DOT-106A***X suffix letters
X = Fusion-welded longitudinal tank seam and forge-welded head seams
XNC = Nickel clad
NCI = Nickel—chromium—iron
Class DOT-107A**** tank cars are uninsulated high-pressure service cars having several perma-
nently mounted seamless, forged, and drawn steel tanks designed to a maximum stress level in
the shell.
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M-1002 CHAPTER 1
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 suf-
fix letters or numerals. Class DOT-111A***F* have forge-welded tanks converted from Specifica-
tion ICC-105A300, 400, or 500. Suffix letters are shown in Table 1.8.
Table 1.8 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.
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 1.9 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
10/2007 C-III [M-1002] 13

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CHAPTER 1 M-1002
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 1.10 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 1.11 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 1.12.
Table 1.12 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.
1.2.3.2 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 1.13 Class AAR-203*W suffix letters
(No letter) = carbon steel
D = alloy steel
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M-1002 CHAPTER 1
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 1.14.
Table 1.14 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 1.15 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 1.16.
Table 1.16 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.
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 1.17.
Table 1.17 Class AAR-211A***W* suffix letters
W1 = Carbon steel tank; 2% minimum expansion capacity in tank; optional
bottom outlet or washout
W6 = Alloy steel, optional bottom outlet or bottom washout
W7 = Alloy steel, no bottom outlet or bottom washout
ALW = Aluminum alloy tank
10/2007 C-III [M-1002] 15

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CHAPTER 1 M-1002
1.2.3.3 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 longitu-
dinal seams.
1.2.3.4 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.
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 require-
ments. 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-specifica-
tion 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 construc-
tion.
1.3.4 Safety Appliances
Safety appliances must comply with the current issue of DOT Railroad Safety Appliance Stan-
dards, 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 autho-
rized in railroad interchange.
A valid Certificate of Construction and, when applicable, Exhibit R–1 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.
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M-1002 CHAPTER 1
1.3.6 Approvals
Design and materials for fabrication, alteration, conversion, or welded repairs must be approved.
Design and materials of all valves and fittings 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.
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.
1.3.7 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 capaci-
ties 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.
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CHAPTER 1 M-1002
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 Gauging—Gauging Petroleum and Petro-
leum 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.
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 under-
frame, 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
and must be reported on Exhibit R–1.
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 R–1. Both old and new numbers must be reported. This is in addi-
tion 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
The following documents must accompany any sale of a tank car, except for scrap:
• Certificate of Construction (Form AAR 4-2)
• Outline of the current owner’s maintenance program (areas of inspection, inspection meth-
ods, inspection frequencies, acceptance criteria)
• Tank car general arrangement, tank arrangement, and fittings arrangement drawings
• Exhibit R–1 and Exhibit R–2 reports, if any, describing modifications or repairs
• For stub sill cars, Form SS-1 (see Fig. R13), SS-2 (no longer current), or SS-3, if any, docu-
menting required inspection of stub sills and attachment welds
• Service reliability assessment data, including the above items, plus the following:
• Qualification reports
• Pressure relief device test certificates
• AAR QA 7.1 Forms
These documents must be maintained for the life of the car.
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M-1002 CHAPTER 1
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 prohib-
ited. 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, Section C.3, and with all aspects of the AAR Manual of Standards and Recommended
Practices, Section C, Standard S-259 (for limited interchange by agreement) or Standard S-286 (for
unlimited interchange service).
1.3.16.1.2 AAR cars must be stenciled AAR Class-211W or Class-204W.
1.3.16.1.3 DOT/TC cars must meet MSRP Standard S-259 (for limited interchange by agree-
ment) or MSRP Standards S-286 and M-1002 Chapter 2, paragraph 2.5 (for unlimited interchange
service) and must have government approval to operate with gross rail load over 263,000 lb.
1.3.16.1.4 Cars must be registered in UMLER with Star Code “L” or “M” as appropriate.
1.3.16.1.5 Cars designed to meet S-259 must be equipped with truck castings manufactured in
1995 and thereafter that are designed and tested to 286,000 lb by the casting manufacturer for
286,000 lb gross rail load. Cars designed to meet S-286 must be equipped with trucks having pre-
liminary, conditional, or full approval under AAR Truck Performance Specification M-976, latest
issue.
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.
1.3.16.3 Existing Cars
1.3.16.3.1 Form AAR 4-2, Application for Approval and Certificate of Construction, must be sub-
mitted 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, specifica-
tions, 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 Inter-
change 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.
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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 pressure relief devices and other valves and fittings will continue to be
approved by the Tank Car Committee in accord with paragraphs 1.4.5 and 1.4.6.
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 sub-
mitted to the Executive Director—Tank 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. The form must be typewritten, hand
printed in a legible manner, or computer generated.
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
Each application, whether for precedent or nonprecedent approval, will be assessed a nonrefund-
able application fee of US $180, payable to the Association of American Railroads. This fee must be
submitted with the original application to AAR, unless a deposit account has been previously
established by the applicant.
In addition, applicants will reimburse the AAR for costs associated with the review of nonprece-
dent applications by an ITP. Deposit accounts established to cover costs of ITP application review
will be reconciled on a periodic basis, and reports will be furnished to applicants on request.
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M-1002 CHAPTER 1
1.4.2.2 Nonprecedent Applications

Nonprecedent applications are those not based on previously approved designs. Applicants must
submit two copies of the application with one set of drawings for the AAR and one copy of the
application with one set of drawings for the ITP. 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. Applications must include prints of drawings and calculations folded to approxi-
mately 8 1/2 × 11 in. in size. All prints must be marked with the application number (assigned by
AAR) with which they are submitted.
The 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
ITP will notify AAR when 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.
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 ref-
erence a design identical to that for which approval is requested or they may contain limited revi-
sions 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 ref-
erenced precedent certificate of construction was approved within the preceding 10 years. The
application may include changes listed in paragraph 1.4.2.4.
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 previ-
ously 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 com-
pliance 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 compo-
nents (see Appendix A, paragraph 1.2.1.6)
• Application of previously approved head shields, thermal protection systems, or insulation
systems or the deletion of such systems
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• Changes to approved head shields, thermal protection systems, or insulation systems nec-
essary 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
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 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 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 fit-
tings
• 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 Chapter 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 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 Section 1.2.1 of AAR Specification M-1001, require approval of the Equipment Engi-
neering 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 Section 1.2.1 of AAR 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 Direc-
tor 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 paragraph 6.3 of this specification and/
or applicable chapters of Specification M-1001.
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M-1002 CHAPTER 1
1.4.2.8 Alteration, Conversion, or Repair

For alterations, conversions, or welded repairs using previously approved procedures and materi-
als, an Exhibit R–1 report in compliance with Appendix R must be submitted. For alterations, con-
versions, 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.
1.4.2.9 Safety Appliances
Safety appliances must be in accord with U.S. Department of Transportation (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 applica-
tion 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 para-
graph 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 com-
mittee 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 applicant’s response. A Committee member having taken exception to an applica-
tion 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 Com-
mittee 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 UMLER file.
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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” por-
tion 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 Construction—Nonprecedent F Construction—Precedent L Construction—Nonprecedent
Committee Ballot AAR Approve AAR Approve
B Conversion—Nonprecedent G Conversion—Precedent M Conversion—Nonprecedent
C Alteration—Nonprecedent H Alteration—Precedent N Alteration—Nonprecedent
D Welded Repair—Nonprecedent J Welded Repair—Precedent P Welded Repair—Nonprecedent
E Other— Nonprecedent K Other—Precedent Q Other—Nonprecedent
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.”
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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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 specifica-
thru tions and thicknesses. When transverse Charpy impact tests are required per
16.
17.
18. paragraph 2.2.1.2, lines 15 and 16 must show material specifications and the impact test
temperature (e.g., “TC128BN TCVN -30F”).
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 pres-
sure 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 kJ•mm/h•m2•°C.
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.
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).
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.”
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Line Instruction
39. Drawings. Enter the drawing number of all drawings relevant to the application in the
thru 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 ref-
erence 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 noth-
ing 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 nonprece-
dent drawings that will require ITP review, in which case all drawings are to be sub-
mitted, including the precedent drawings.
c. If a cited drawing is based on a previously approved drawing, but with changes permit-
ted under paragraph 1.4.2.4, enter the precedent drawing number in the second col-
umn 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 pre-
cedent 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 be folded
to approximately 8 1/2 × 11 in. in size, must carry a current approval signature or ini-
tial 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.
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.
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10/2007
M-1002 CHAPTER 1
1.4.3.1.6 Applications submitted by facilities other than the tank fabricator for assembly of new
tank cars must be accompanied by a statement under “Notes” that “Tank fabrication by . . . [certi-
fied facility (a currently certified Class A or D facility)]. Completed car will comply with all appli-
cable 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 construc-
tion. 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 1.4.8 and Appendix A,
paragraph 1.3.
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 calcu-
lations 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 applica-
tion.
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.
10/2007 C-III [M-1002] 27

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

Page 1 of
1 APPROVAL REQUESTED OF: PRECEDENT 2 TYPE: CONSTRUCTION WELDED REPAIRS 3 AAR NO.
NONPRECEDENT ALTERATION OTHER 4 DATE:
CONVERSION 5 APPLICANTS NO.
6 APPLICANT: 7 TANK SPECIFICATION:
8 STENCILED SPEC.:
9 REPORTING MARKS & CAR NUMBERS 10 NUMBER OF CARS
11 Initial commodity 12 Density, lb, per gal

13 Full water capacity, gal 14 Dome capacity or outage, gal
15 Material type and grade—heads 16 Material type and grade—shell
17 Material thickness—heads, in. 18 Material thickness—shell, in.
19 Lining type 20 Inside diameter—center, in.
21 Inside diameter—end rings, in. 22 Head radius, main, in. (if not 2:1)
23 Test pressure, psi 24 Insulation type
25 Insulation thickness, in. 26 Thermal conductivity, Btu-in/hr—ft2-F
27 Type and number of pressure 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, in. 34 Est. light weight, lb
35 AAR clearance diagram 36 Rail load limit, lb
37 Truck capacity, tons 38 Head shields
Notes:
Original Certificate_______________________________
Builder ________________________________________
Date__________________________________________
Former lading __________________________________
The Following Prior Approvals Apply:

The Following Drawings Apply: Drawing Number Drawing Number Application/Certificate No.
39 General Arrangement……………………………
40 Tank Arrangement………………………………
41 Reinforced 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 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_____________________________________________________
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 Revised 12/1/00
Fig. 1.1 Form AAR 4-2 Application for Approval and Certificate of Construction
(Click here to access a printable form)
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M-1002 CHAPTER 1
AAR No. __________________________
Applicant’s No. _____________________
Date _____________________________
APPLICATION BY: __________________________________________

SIGNATURE _______________________________________________
TITLE_____________________________________________________
Date Approved _____________________________________________

(signature) on behalf of the Tank Car Committee
Form AAR 4-2.1 Revised 12/1/00 Page of
Fig. 1.2 Form AAR 4-2.1 Supplementary page

10/2007 C-III [M-1002] 29
10/2007
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 Cer-
tificate 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.
1.4.4.1.2 For all tank cars built, the facility assembling the completed cars must furnish a Certif-
icate of Construction, Form AAR 4-2, to the owner and the Director certifying that tank, equip-
ment, and car comply with all the requirements of the specifications. (For Class DOT-107A, see
also 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 Direc-
tor. One copy of the Certificate of Construction must be furnished to the Director for each car num-
ber 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, certi-
fied inspector’s reports as required by DOT 179.500-18 must be submitted.
1.4.5 Pressure Relief Devices
1.4.5.1 Approval of Pressure Relief Devices (Form AAR 4-3)
1.4.5.1.1 Application for approval of designs of pressure relief devices must be submitted in
accord with the procedure in Appendix A, paragraph 6.3.
1.4.5.1.2 To secure approval as required by paragraph 1.3.6, application for approval of design,
material, and flow capacity rating must be submitted by the applicant to the Tank Car Committee
on Form AAR 4-3, Application for Approval of Pressure Relief Devices. Applications must include
prints of drawings, the flow test facility’s report, and calculations, as required, folded to approxi-
mately 8 1/2 × 11 in. in size. All submitted materials must be marked with the number of the
application with which they are submitted.
1.4.5.2 Application Form AAR 4-3
Applications for Approval of Pressure Relief Devices, Form AAR 4-3, must be typewritten or
printed in a legible manner and must be accompanied by a fee of US $180.
1.4.5.2.1 Instructions
1.4.5.2.1.1 The following instructions must be followed by the applicant when completing the
application and certification portions of the form:
• AAR number must be furnished by the Director.
• The applicant must be the valve manufacturer.
• The date must be that on which the application is completed.
• The applicant’s number blank is for the convenience of the applicant.
• The device identification number is for the convenience of the applicant (e.g., catalog num-
ber).
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M-1002 CHAPTER 1
1.4.5.2.1.2 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 approved test facility.
4. Record the date the flow rating tests were conducted.
5. Write the authorized observer’s name here.
6. Record the identity of each device tested, as required in Appendix A, paragraph 6.2.
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 Ap-
pendix A, paragraph 6.2).
12. Enter the proper shipping names for the specific commodities for which the device is in-
tended.
13. Drawings. Under these items, all drawings relevant to the application must be listed in
thru the first column headed “Drawing Number.” Information for columns two and three under
16. “Precedent” shall be determined by the appropriate following instructions:
a. If a drawing has been previously approved by the Tank Car Committee, enter the cer-
tificate 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 sep-
arate 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.
f. All drawings submitted with Form AAR 4-3 must carry a current approval signature
or initial by the proponent.
1.4.5.2.2 Certification
The applicant signs the form under “Certification” attesting to the above entries.
1.4.5.2.3 Approval
The Director completes the “Approval” portion of the form based on action taken on the applica-
tion.
10/2007 C-III [M-1002] 31

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

Applicant’s No.
APPROVAL REQUESTED OF AAR TANK CAR COMMITTEE Date
Device identification No.
Applicant
1. Manufacturer
Address
2. Test facility 3. 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. Commodities
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 AAR Tank Car Committee
Date Approved
* 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.
Fig. 1.3 Form AAR 4-3 Application for Approval of Pressure Relief Device
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10/2007
M-1002 CHAPTER 1
1.4.6 Valves and Fittings

1.4.6.1 Approval of Valves and Fittings (Form AAR 4-5)
To secure approval of valves and fittings as required by paragraph 1.3.6, application for approval
of design and materials must be submitted by the applicant to the Tank Car Committee on Form
AAR 4-5, Application for Approval of Valves and Fittings. Applications must include prints of
drawings and calculations, as required, folded to approximately 8 1/2 × 11 in. in size. All submitted
material must be marked with the number of the application with which they are submitted.
Applications for Approval of Valves and Fittings (other than pressure relief devices), Form AAR 4-
5, must be typewritten or printed in a legible manner and must be accompanied by a fee of
US $180.
application and certification portions of the form.
• AAR number will be furnished by the Director.
• AAR docket number is the number assigned by the Director to review a specific item when
required by the Tank Car Committee.
• AAR service trial number will be issued by the Director at the time the application is pro-
cessed, at the request of the Tank Car Committee, to collect service data on the device.
• Applicant must be the manufacturer of the device.
• Describe the device and its function in accord with the definitions and requirements of
Appendix A.
• Spaces for the applicant’s number and the device identification number are for the conve-
nience of the applicant (e.g., index, catalog, or type numbers).
• The date must be that on which the application is completed.
Line Instruction
1. Identify the manufacturer of the device.
2. Record the test facility that tested the device, if other than the manufacturer’s.
3. Record the date testing was completed for subject device.
4. Indicate the authorized observer’s name.
5. Indicate the weight, or weight and mass, of device assembly.
6. Indicate the procedure used to test the prototype device and the number of devices tested.
7. Indicate the procedure used to test the initial service trial devices and the number of
devices tested.
8. Indicate the number of cycles to which the 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.).
9. Indicate the number of cycles to which the device was subjected at high and low pressures
and at the given temperature, as well as the specific testing medium used (e.g., air, water,
etc.).
10. Indicate the commodity or commodity type.
11. Indicate the flow rate of the device in gallons per minute, or gallons per minute and liters
per minute, if applicable.
10/2007 C-III [M-1002] 33

10/2007
CHAPTER 1 M-1002
Line Instruction
12. 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.
13. Indicate the drawing number of the device assembly and basic material and, when
applicable, reference a precedent drawing with AAR application number.
14. Indicate the drawing number and material specification of individual parts.
15. Provide a basic statement that the facility has a quality control program to provide
compliance with drawings and specifications.
1.4.6.2.2 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.
1.4.6.2.3 Approval
tion.
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10/2007
M-1002 CHAPTER 1
APPLICATION FOR APPROVAL OF VALVES AND FITTINGS

Applicant AAR No.
Description of Device
Applicant No. Device Ident. No. Date

1. Manufacturer
Address City State Zip
2. Test facility Address
TEST PROCEDURE: 5. Weight or mass of device lb. (_______ kg)
6. Description of prototype testing:
7. Description of production testing:
8. Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
________ __________ºF _________psi ________ __________ºF ________psi ____________
________ __________ºC ________kPa ________ __________ºC _______kPa ____________
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
________ __________ºF _________psi ________ __________ºF ________psi ____________
________ __________ºC ________kPa ________ __________ºC _______kPa ____________
9. Cycles Min. Pressure @ Temp. Cycles Max. Pressure @ Temp. Test Medium Remarks
________ __________psi _________ºF ________ _________psi ________ºF ____________
________ _________kPa _________ºC ________ _________kPa ________ºC ____________
Cycles Min. Pressure @ Temp. Cycles Max. Pressure @ Temp. Test Medium Remarks
________ __________psi _________ºF ________ _________psi ________º F ____________
________ _________kPa _________ºC ________ _________kPa ________ºC ____________
10. Initial commodity (or commodity type) __11. Flow rate (if applicable) __gpm (_________L/min)
Drawing Number Precedent

Applicable drawings Material latest revision Drawing Number Application/Certificate
12. Device application . . . . . .
13. Device assembly . . . . . . . .
14. Device details . . . . . . . . . .
15. 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
Date Approved
Form AAR 4-5 Revised 12/1/2000 Subject to AAR Service Trial No. _____________
Fig. 1.4 Form AAR 4-5 Application for Approval of Valves and Fittings
10/2007 C-III [M-1002] 35
10/2007
CHAPTER 1 M-1002
1.4.7 Renewal of Approval for Valves and Fittings

1.4.7.1 Requirements for Renewal of Approval
Renewal of previously approved valves and fittings, as well as changes in these devices, must be
submitted to the Tank Car Committee on Form AAR 4-7, Application for Renewal of Approval for
Valves and Fittings. Applications must include prints of drawings and calculations, as required,
folded to approximately 8 1/2 × 11 in. in size. All submitted material must be marked with the
AAR approval number with which they are submitted.
Applications for Renewal of Approval for Valves and Fittings must be typewritten or printed in a
legible manner and must be accompanied by a fee of US $180.
1.4.7.2.1 Instructions for Unchanged Devices
Line Instruction
1. AAR approval number will be furnished by the Director.
2. Record the date the form is submitted.
3. Enter the previous AAR approval number under which the device was approved by the
Tank Car Committee.
4. Enter the applicant’s name and address.
5.
6. Provide an applicable drawing number of the valve or fitting with the latest revision and
7. its date.
8.
9. Spaces for a description designation and device identification number are for the
10. convenience of the applicant (e.g., index, catalog, type numbers).
1.4.7.2.2 Certification
Line Instruction
11. The applicant signs the “Certification,” attesting to the above entries. Enter the applicant’s
title.
1.4.7.2.3 Instructions for Changed Devices
Line Instruction
12. Identify the previous and current drawings.
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.
1.4.7.2.4 Certification (Line 17)
The applicant signs the “Certification,” attesting to the above entries. Enter the applicant’s title.
1.4.7.2.5 Approval
tion.
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M-1002 CHAPTER 1
APPLICATION FOR RENEWAL OF APPROVAL FOR VALVES 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 12/1/2000
Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Valves and Fittings
10/2007 C-III [M-1002] 37
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CHAPTER 1 M-1002
1.4.8 AAR Service Trials

1.4.8.1 Authorization for Service Trials
1.4.8.1.1 For the operation of AAR specification tank cars in nonregulated commodity service
when such tanks or equipment therefor are not in compliance with effective AAR specifications,
the AAR Tank Car Committee may authorize service trials.
1.4.8.1.2 For the operation of DOT or AAR specification tank cars in regulated or nonregulated
commodity service when such tanks and related equipment are in compliance with effective DOT
and AAR specifications but, in the opinion of the AAR Tank Car Committee, some component
should be subject to a period of surveillance and evaluation, the Committee may require service
trials.
1.4.8.1.3 When a request is made for an AAR service trial authorization, the owner must submit
to the Director complete information justifying the issuance of a permit for service trial.
1.4.8.1.4 On Form AAR 4-2 in the space for “Notes,” the statement “AAR Service Trial No.__”
must be indicated. The Certificate of Construction must be submitted before the car is placed into
trial service.
1.4.8.1.5 Service history for a component covered by an AAR service trial authorization will be
maintained by the owner. Periodic reports will be submitted to the AAR as specified by the Tank
Car Committee. If a service trial has been initiated but not completed and no reports have been
received by AAR for a period of 2 years, the Tank Car Committee may, at its discretion, terminate
the service trial.
1.4.8.1.6 See Appendix A, paragraph 1.3, for sample size and post-trial teardown requirements
for valves and fittings.
1.4.8.2 Service Trial Report Form AAR 4-4
Service trial data as required by paragraph 1.4.6.2.3 and Appendix A, paragraph 1.3, when
requested by the Tank Car Committee (see also paragraph 1.4.3.1.7), must be submitted on Form
AAR 4-4, AAR Tank Car Service Trial Report, at six-month intervals on April 1 and October 1 of
each year, to the Director. Failure to submit the report may result in cancellation of service trial
authorization.
1.4.8.2.1.1 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.
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 applicant’s 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.
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M-1002 CHAPTER 1
1.4.8.2.1.2 Enter the numbered items as follows:
Line Instruction
1. Spaces for the applicant’s number and device identification number are for the
2. convenience of the applicant (e.g., index, catalog, or type 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 number of loaded trips the car has made during the period covered by the
report.
9. Indicate the approximate total miles, or miles and kilometers, the car moved in the period
covered by the report.
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.
thru
17.
18.
1.4.8.2.1.3 Applicant or applicant’s representative signs the form.
10/2007 C-III [M-1002] 39

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CHAPTER 1 M-1002
AAR TANK CAR SERVICE TRIAL REPORT*
AAR No.
AAR Docket No.
Reporting company AAR Service Trial No.
Address Date
Covering Period
1. Applicant’s No. 2. Device ident. No. 3. Date initial installation

4. Description of device
5. Number cars authorized to applicant Number of cars this report
This Report 10. To Date

9. Distance Distance
6. Reporting Marks 7. Commodity 8. Loaded Loaded
Trips Miles Km Trips Miles Km
AVERAGES
11. Loading temperature ºF ( ºC) 12. Unloading temperature ºF ( ºC)

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.
*NOTE: This report to be furnished at six month intervals, April 1st and October 1st, and submitted to the Director. Failure to submit
report may result in cancellation of service trial permit.
Submitted by Title
Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report
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M-1002 CHAPTER 1
1.4.9 Final Product Test and Inspection

1.4.9.1 Final Product Test and Inspection Report Form AAR 4-6
The guidelines for acceptance of a service trial (see Appendix A, paragraph 1.3) require a report of
post-trial teardown to be filed on Form AAR-4.6.
Final Product Test and Inspection Report. This form must be submitted to the Director for distri-
bution 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.
requested by the Tank Car Committee.
• AAR service trial number is the number assigned to the device for which this report is pre-
sented.
• 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. (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 Appendix A,
paragraph 1.3 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. These entries are for general comments and conclusions leading to the formal
11. recommendation to the Tank Car Committee.
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.
1.4.9.1.1.3 The samples examined must have had the full range of service trial experience.
10/2007 C-III [M-1002] 41

10/2007
CHAPTER 1 M-1002
FINAL PRODUCT TEST AND 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 from latest Form AAR 4-4 dated
Total load/unload cycles Total loaded mileage
Total service time
8. Teardown data Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

From car number………………
Last lading…………………….
Model number…………………
Serial number………………….
Test pressure, psi (kPa)………..
Test temperature, °F (ºC)……….
Test medium…………………...
Cycles………………………….
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
(Signature) (Signature)
Title Title
Company Company
13. APPROVAL AAR Tank Car Committee
Date approved
NOTE: The AAR Tank Car Committee reserves the right to designate an independent observer to be present during test and teardown activity.
Form AAR 4-6 Revised 10-17-86
Fig. 1.7 Form AAR 4-6 Final Product Test and Inspection Report
C-III [M-1002] 42 10/2007

10/2007
M-1002 CHAPTER 1
1.4.10 Certified Status

1.4.10.1 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:
1.4.10.1.1 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 materials, length of slabs, etc., are to be tab-
ulated on the drawing.
1.4.10.1.2 Two tabulations are to be prepared as follows:
1.4.10.1.2.1 Car tabulation(s) by type of stub sill (underframe) showing car numbers (or car num-
ber series where applicable).
1.4.10.1.2.2 Tabulation by car number, showing the following:
• Type of stub sill construction
• Length over strikers
• Truck centers
• Truck capacity
• Capacity, gallons (liters)
• Tank materials—at 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 diameter (inside)
• Year built new
1.4.10.1.3 Submit test data as specified in Section 6.3 of AAR Specification M-1001.
1.4.10.1.4 Submit stress calculations as specified in Section 6.2 of AAR Specification M-1001.
Include a comparison summary of calculated and measured stresses.
1.4.10.2 Approval
1.4.10.2.1 When approved by the Equipment Engineering Committee and the Tank Car Commit-
tee, 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.
1.4.10.2.2 The car owner must periodically submit to the AAR a listing of car modifications and
stenciling dates, if so requested.
1.4.10.2.3 In the event forthcoming tests or in-service operation proves the design inadequate, a
reevaluation of a certified status approval will be made.
10/2007 C-III [M-1002] 43

10/2007
CHAPTER 1 M-1002
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 third party (ITP) who verifies that the applica-
tions meet all AAR, DOT, and Transport Canada requirements. This section sets forth the mini-
mum 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 Sci-
ence degree in an engineering discipline conferred by an accredited college or university. Registra-
tion 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 five 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 Cana-
dian federal regulations governing tank car design, construction, and repair, AAR Interchange
Rules, and AAR Standards and Recommended Practices—particularly M-1002. An ITP must pos-
sess or have access to the above documents as well as to relevant American Welding Society and
American Society of Testing and Materials 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 con-
tract 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.
C-III [M-1002] 44 10/2007

10/2007 Specifications for Tank Cars
M-1002 CHAPTER 2
CHAPTER 2
AAR SPECIAL REQUIREMENTS FOR DOT TANK CARS
CONTENTS

2.1 Special Commodity Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–47
2.1.1 Argon, Carbon Dioxide, Nitrogen, and Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–47
2.1.2 Hydrogen Sulfide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–47
2.1.3 Molten Sulphur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–48
2.1.4 Hydrogen Fluoride, Anhydrous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–48
2.1.5 Vinyl Chloride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–49
2.1.6 Aluminum Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–50
2.1.7 Totally Contained Commodities (Shipped in Tank Cars not Equipped with Pressure Relief Devices)C-III–50
2.1.8 Ammonia, Anhydrous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–50
2.1.9 Chlorine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–51
2.2 General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–52
2.2.1 Pressure Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–52
2.2.2 Manway Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–52
2.2.3 Fittings for Acid Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–52
2.2.4 Eduction Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–54
2.2.5 Two-Bolt Swing Closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–54
2.2.6 Lead Rupture Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–54
2.2.7 Vacuum Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–54
2.2.8 Electrical Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–54
2.2.9 Internal Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–54
2.2.10 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–54
2.2.11 Bottom Outlet Caps and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–55
2.2.12 Internal Heater Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–55
2.2.13 Gas Purging Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–55
2.2.14 Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–55
2.2.15 Thermal Protection Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–55
2.2.16 Re-Stenciling AAR Class Cars to DOT/TC Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–56
2.3 Special Requirements (Proposed Revisions to DOT Specifications). . . . . . . . . . . . . . . . . . . . . . . . . . C-III–56
2.3.1 AAR Special Requirements for DOT Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–56
2.4 Shipper Requirements in Addition to DOT Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–57
2.4.1 Outage Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–57
10/2007 C-III [M-1002] 45

CHAPTER 2 M-1002

2.5 Requirements for DOT/TC Tank Cars Weighing Over 263,000 lb GRL. . . . . . . . . . . . . . . . . . . . . . . . .C-III–57
2.5.1 All Class DOT/TC Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–57
2.5.2 Class DOT/TC-111 Nonpressure Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–57
2.5.3 Class DOT/TC Pressure Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–58
2.5.4 Class DOT/TC-113 Cryogenic Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–58
2.5.5 Class DOT/TC-115 Nonpressure Tank Cars (tank within a tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–58
C-III [M-1002] 46 10/2007

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:
2.1.1.2 Stencil “REGULATING VALVE(S) (VENTING NORMAL),” “RELIEF VALVE,” or “RUP-
TURE DISC” in 1-in. letters, minimum, over or under the discharge pipes from the respective
devices.
2.1.1.3 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. C2.
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 treat-
ment.
2.1.2.2.2 Tank must be postweld heat treated at 1100 °F (593 °C) minimum; postweld heat treat-
ment 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 (621MPa) 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 Asso-
ciation 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.
2.1.2.2.6 Vacant
2.1.2.2.7 Special tank material requirements:
2.1.2.2.7.1 Tank cars intended to be loaded at ambient temperatures must be constructed of steel
listed above that has not less than 20 ft-lb (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.”
2.1.2.2.7.2 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 ft-lb (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.”
10/2007 C-III [M-1002] 47

CHAPTER 2 M-1002
2.1.2.2.7.3 Impact testing must conform to ASTM A370 and Appendix W, except that all test and
retest specimens (not the average) must meet the requirements.
2.1.2.2.8 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.
2.1.2.2.9 Lead-base paints and lead gaskets must not be used.
2.1.2.2.10 Tank jacket must be stenciled on both sides in letters not less than 4 in. (102 mm) high
“HYDROGEN SULFIDE.”
2.1.2.2.11 All loose mill scale must be removed from the interior of the tank using Steel Struc-
tures 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-resis-
tant material applied in areas of high heat flux to prevent wet elemental sulphur contact corro-
sion. 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 trans-
port anhydrous hydrogen fluoride must be met. See Appendix R, paragraph 5.1, 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 is prohibited.
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 maxi-
mum 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 ultrasoni-
cally scanned per ASTM A-578, Level C (using a 1-in. circle).
2.1.4.3 Tanks must be postweld heat treated between 1125 °F and 1225 °F. Postweld heat treat-
ment 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 5.1.
2.1.4.5 The maximum hardness of the tank and welds after postweld heat treatment must be
20 HRC. If weld repairs are required, hardness measurements shall be made per Appendix R,
paragraph 5.1.
C-III [M-1002] 48 10/2007

M-1002 CHAPTER 2
2.1.4.6 Valves, valve parts, and other appurtenances normally in contact with the lading must
comply with National Association of Corrosion Engineers Publication MR-01-75 or be of the follow-
ing 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 rup-
ture 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 rup-
ture 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-B7—Maximum hardness Brinell 237 (Rc 22)
• ASTM A320-L7—Maximum 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.
2.1.4.9 Nuts used to fasten any valves or fittings to the cover plate or the cover plate to the man-
way ring must meet one of the following specifications:
• ASTM A194-2HM including Supplement S7 requiring 100% hardness testing
• ASTM A194-2—Maximum 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 Corro-
sion Engineers Publication MR-01-75 and must be approved for anhydrous hydrogen fluoride ser-
vice. Ferritic stainless steels must not be used.
2.1.4.11 Each tank must be marked “HYDROGEN FLUORIDE” in accord with DOT 172.330.
2.1.4.12 Inspection and Repairs
See Appendix R, paragraph 5.1.
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. E9 (20-in. diameter) or Fig. E11 (22-in. diameter). Refer to
Fig. E10 (20-in.-diameter cover plate) or Fig. E12 (22-in.-diameter cover plate) for details on nozzle
joints. For details on openings, see Figs. E19 through E19.25.
10/2007 C-III [M-1002] 49

CHAPTER 2 M-1002
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 Pres-
sure Relief Devices)
2.1.7.1 The transportation of totally contained commodities in tank cars not equipped with pres-
sure 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 trans-
portation 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 AAR Form 4-2 (see Fig. 1.1 on page
C-III–28), requesting approval. Technical justification must be submitted with the application and
must include calculations made with the AFFTAC simulation model or approved equivalent analy-
sis, 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 6.1.
2.1.8 Ammonia, Anhydrous
2.1.8.1 Definitions
Base car 100-ton 112J340W car with 115.909 in. inside diameter, 0.608-in.-thick heads and
shell, TC128 steel, 1/2-in.-thick ceramic fiber or mineral wool, and 11 gauge steel
jacket with full height 1/2-in.-thick head shields.
Car owner The owner of the reporting mark stenciled on the car. Where multiple owners
exist under one reporting mark, the Owner's Mark field in UMLER is to be used.
CPR Conditional Probability of Release
HS Expected reduction in CPR resulting from changes to the head shields.
H Expected reduction in CPR resulting from changes to the heads.
JT Expected reduction in CPR resulting from changes to the jacket.
S Expected reduction in CPR resulting from changes to the shell.
2.1.8.2 Implementation
Car owners are to provide plans that must provide for compliance (per paragraph 2.1.8.3) for 100%
of their fleet used to transport anhydrous ammonia by December 31, 2018. Plans must be consid-
ered and approved by the Tank Car Committee. Car owners are to submit implementation plans to
AAR by December 31, 2008, and provide progress reports by March 31 each year. For purpose of
measuring compliance with the fleet reduction requirements described above, starting fleet size
will be determined on the date an implementation plan is submitted to AAR, but no later than
December 31, 2008.
C-III [M-1002] 50 10/2007

M-1002 CHAPTER 2
2.1.8.3 New and Existing Cars

Effective January 1, 2008, tank cars ordered built new for anhydrous ammonia service must com-
ply with DOT specification 112J500W and be equipped with full-height 1/2-in.-thick or equivalent
head shields and top fittings protection in accord with paragraph 2.1.8.4. Alternatively, cars may
comply with the following:
Tank cars that have been equipped with top fittings protection in accord with
paragraph 2.1.8.4 and built or modified to demonstrate a 32% or greater reduction
in CPR relative to the base car using the following formula are also acceptable:
(HS+H) + (JT+S) ≥ 32%
Alternative validation methodology and analysis techniques may be utilized, sub-

ject to approval by the AAR Tank Car Committee.
2.1.8.4 Top Fittings Protection

Top fittings protection must be designed to withstand, without loss of lading except through the
pressure relief device, a rollover with a linear velocity of 9 mph minimum, applied at the geometric
center of the loaded tank as a transverse vector. The rolling surface is assumed to be flat, level,
and rigid.
2.1.9 Chlorine
2.1.9.1 Definitions
Base car 90-ton 105A500W car with 102-in. inside diameter, 0.787-in.-thick heads and
shell, TC128 steel, 2-in. fiberglass insulation over 2-in. ceramic fiber or mineral
wool, and 11 gauge steel jacket and jacket heads.
Car owner The owner of the reporting mark stenciled on the car. Where multiple owners
exist under one reporting mark, the Owner's Mark field in UMLER is to be used.
CPR Conditional Probability of Release
HS Expected reduction in CPR resulting from changes to the head shields.
H Expected reduction in CPR resulting from changes to the heads.
JT Expected reduction in CPR resulting from changes to the jacket.
S Expected reduction in CPR resulting from changes to the shell.
2.1.9.2 Implementation
Car owners are to provide plans that must provide for compliance (per paragraph 2.1.9.3) for 100%
of their fleet used to transport chlorine by December 31, 2018. Plans must be considered and
approved by the Tank Car Committee. Car owners are to submit implementation plans to AAR by
December 31, 2008, and provide progress reports by March 31 each year. For purpose of measuring
compliance with the fleet reduction requirements described above, starting fleet size will be deter-
mined on the date an implementation plan is submitted to AAR, but no later than December 31,
2008.
10/2007 C-III [M-1002] 51

CHAPTER 2 M-1002
2.1.9.3 New and Existing Cars

Effective January 1, 2008, tank cars ordered built new for chlorine service must comply with DOT
specification 105J600W and be equipped with full-height 1/2-in.-thick or equivalent head shields
and top fittings protection in accord with paragraph 2.1.9.4. Alternatively, cars may comply with
the following:
Tank cars that have been equipped with top fittings protection in accord with
paragraph 2.1.9.4 and built or modified to demonstrate a 45% or greater reduction
in CPR relative to the base car using the following formula are also acceptable:
(HS+H) + (JT+S) ≥ 45%
Alternative validation methodology and analysis techniques may be utilized, sub-

ject to approval by the AAR Tank Car Committee.
2.1.9.4 Top Fittings Protection

Top fittings protection must be designed to withstand, without loss of lading except through the
pressure relief device, a rollover with a linear velocity of 9 mph minimum, applied at the geometric
center of the loaded tank as a transverse vector. The rolling surface is assumed to be flat, level,
and rigid.
2.2 General Requirements
2.2.1 Pressure Tank Car Tanks
2.2.1.1 All steel, single-unit pressure tank car tanks must be fabricated from fine-grain steels as
described by ASTM A516, A537 or TC128. Heads and shells of pressure tank car tanks constructed
of ASTM A516 or TC128 must be normalized, effective January 1, 1989. Tank car heads must be
normalized after forming, unless specific approval is granted for a facility’s equipment and con-
trols.
2.2.1.2 Effective for cars ordered after August 1, 2005, each plate-as-rolled of ASTM A516, A302,
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 ft·lb average for three specimens, with no single value below 10 ft·lb and no two below 15 ft·lb at
–30 ºF. Plates for low-temperature service described in 49 CFR 179.102 that require longitudinal
impact testing at –50 ºF do not require transverse testing at –30 ºF.
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 pres-
sure 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.
C-III [M-1002] 52 10/2007
M-1002 CHAPTER 2
2.2.3.3 Subject to paragraph 2.2.3.4, the service equipment fitted on top of nonpressure cars in
sulfuric acid service must meet the conditions listed in paragraph 2.2.3.5 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.
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 noz-
zle 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 conditions listed in paragraph 2.2.3.5 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 nozzle's
flange and no more than 20 in. above the outer longitudinal centerline of the tank shell as
shown in Fig. E25.4.
10/2007 C-III [M-1002] 53

CHAPTER 2 M-1002
2.2.3.5 The protective device or unprotected service equipment under consideration must with-
stand 1W 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 under consideration. For horizontal loads, the height of the pro-
jected plane is from the top of the tank at the centerline to the height of the item. 1W is the car's
maximum gross weight on rail minus the weight of the trucks. The stress must not exceed the fol-
lowing:
• The minimum specified tensile strength of the material for the tank, service equipment,
and protective device; and
• The critical buckling stresses of the assembly under consideration.
2.2.4 Eduction Pipes
The following applies to all pressure and nonpressure tank cars, with and without interior coat-
ings or linings:
2.2.4.1 Eduction pipes and guides must be designed and installed to prevent contact of the educ-
tion 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 deflec-
tion that may occur due to design loads as specified in 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
The car design must meet the electrical bonding requirements of AAR Specification M-1001, para-
graph 4.3.6.
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 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.
C-III [M-1002] 54 10/2007

M-1002 CHAPTER 2
2.2.11 Bottom Outlet Caps and Nozzles

The limiting wear dimensions for bottom outlet caps and nozzles are found in Appendix E,
Figs. E18 through E18.5. Caps or nozzles worn to these limits must be removed from service. Sug-
gested NOGO gauges are shown in Figs. E18.6 through E18.9. 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 Definitions.
The following definitions apply to this standard:
2.2.13.1.1 Purging. The replacement of air or other vapors in a tank car by introducing gaseous
nitrogen or 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.
2.2.13.1.2 Padding. The introduction of an inert gas under pressure into the vapor space of a tank
car tank in order to create a nonflammable or moisture-free atmosphere.
2.2.13.2 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.
2.2.13.3 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.
2.2.14 Pressure Relief Valves
Tank cars in regulated commodity service that are equipped with pressure relief valves incorporat-
ing 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 lad-
ing 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 over-
turned 120º 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 46 °C (115 °F) for a noninsulated
tank car, 43 °C (110 °F) for a tank car having a thermal protection system, or 41 °C (105 °F) 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.
10/2007 C-III [M-1002] 55

CHAPTER 2 M-1002
2.2.15.3.4 Surface emissivity of tank 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.
2.2.15.3.6 The pool fire analysis shall use a fire with a minimum temperature of 1,500 °F. The
torch fire analysis shall use a fire with a minimum temperature of 2,200 °F.
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 func-
tion 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 specifica-
tion.
2.2.16.2 At the time of conversion, cars must be qualified to the DOT/TC specification in accor-
dance with the applicable federal regulation.
2.2.16.3 Identification plates have been added or replaced in accordance with the applicable fed-
eral regulation and with Appendix C, paragraph 4.0.
2.2.16.4 The proponent must submit a Form 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 ruptur-
ing the tank 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-ft-lb (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).
C-III [M-1002] 56 10/2007

M-1002 CHAPTER 2
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 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 protective device. In both cases, the calculated
loads must be based on the combined tensile and shear stress.
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 trans-
portation. 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 AAR Manual of Standards and Recom-
mended Practices, Section C, Standard S-286, latest version.
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 higher 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 10.2.
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 have heads and shells constructed
of normalized TC128 Grade B steel. Tank car heads must be normalized after forming, unless spe-
cific approval is granted for a facility's equipment and controls. Non-jacketed tanks must be at
least 1/2 in. thick and be equipped with half-head shields. Jacketed tanks must be at least 7/16 in.
thick and be equipped with 1/2-in.-thick jacket heads.
10/2007 C-III [M-1002] 57
CHAPTER 2 M-1002
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.
C-III [M-1002] 58 10/2007

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-III–61
3.1.1 (AAR.100-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
3.1.2 (AAR.100-2) Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
3.1.3 (AAR.100-4) Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
3.1.4 (AAR.100-10) Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
3.1.5 (AAR.100-11) Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
3.1.6 (AAR.100-16) Gauging Devices, Top Loading and Unloading Devices, Venting Devices, and Air
Inlet Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
3.1.7 (AAR.100-17) Bottom Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
3.1.8 (AAR.100-18) Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–62
3.1.9 (AAR.100-24) Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–62
3.1.10 (AAR.100-25) Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–62
3.1.11 (AAR.100-26) Certificate of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–62
3.2 (AAR.200) Specifications Applicable to Class AAR-204W Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . C-III–62
3.2.1 (AAR.200-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–62
3.2.3 (AAR.200-4) Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–62
3.2.4 (AAR.200-5) Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–63
3.2.5 (AAR.200-6) Bursting Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–63
3.2.6 (AAR.200-8) Thickness of Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–63
3.2.7 (AAR.200-11) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–63
3.2.9 (AAR.200-18) Test of Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–63
3.2.10 (AAR.200-20) Pressure Relief Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–63
3.2.11 (AAR.200-24) Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–64
3.2.13 (AAR.200-26) Certification of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–64
3.3 (AAR.300) Specifications Applicable to Class AAR-206W Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . C-III–64
3.3.1 (AAR.300-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–64
3.3.3 (AAR.300-10) Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–64
3.4 (AAR.400) Specifications Applicable to Class AAR-207W Pressure Differential Covered Hopper
Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
10/2007 C-III [M-1002] 59
CHAPTER 3 M-1002
3.4.1 (AAR.400-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65

3.4.3 (AAR.400-3) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
3.4.4 (AAR.400-4) Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
3.4.6 (AAR.400-6) Thickness of Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–66
3.4.8 (AAR.400-8) Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–67
3.4.9 (AAR.400-9) Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–67
3.4.11 (AAR.400-11) Car Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–68
3.4.12 (AAR.400-12) Hatch Nozzles, Covers, and Openings in Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–68
3.4.13 (AAR.400-13) Internal Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–68
3.4.14 (AAR.400-14) Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–68
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-III–68
3.4.17 (AAR.400-17) Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–69
3.4.18 (AAR.400-18) Tests of Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–69
3.4.22 (AAR.400-22) Qualification and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–70
3.4.23 (AAR.401) Individual Specification Requirements Applicable to Class AAR-207W Pressure
Differential Covered Hopper Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–70
3.5 (AAR.500) Specifications Applicable to Class AAR-208 Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . C-III–72
3.5.1 (AAR.500-1) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–72
3.5.3 (AAR.500-3) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–72
3.5.5 (AAR.500-5) Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–72
3.5.6 (AAR.500-6) Tank Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–72
3.5.7 (AAR.500-7) Manway, Filling, and Discharge Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–72
3.5.8 (AAR.500-8) Tank Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–72
3.5.9 (AAR.500-9) Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–72
3.5.10 (AAR.500-10) Painting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–73
3.5.13 (AAR.500-13) Test of Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–73
C-III [M-1002] 60 10/2007

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 shown in Table 3.1 (see DOT 179.200 and 179.201) except as provided in
the following paragraphs. 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 tanks must conform to DOT-179.200-17 except that external
valves may be of any approved design.
10/2007 C-III [M-1002] 61

CHAPTER 3 M-1002
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 Tagliabue’s 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 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 a tank is not radioscoped or is not postweld heat treated, it 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 tanks are for use in the transportation of liquid argon, liquid nitrogen, or liquid
oxygen.
3.2.1.2 Tanks 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% oxy-
gen 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.
C-III [M-1002] 62 10/2007

M-1002 CHAPTER 3
3.2.4 (AAR.200-5) Materials

Plate material used to fabricate the inner container and appurtenances must comply ASTM Speci-
fication 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.
W1B) and subjected to the tests specified in Appendix W, paragraph 9.0. 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 pres-
sure 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 8.2.2.
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 trans-
port 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.
10/2007 C-III [M-1002] 63

CHAPTER 3 M-1002
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-load-
ing pressure relief valve need not be retested nor should a stencil be used.
3.2.11 (AAR.200-24) Stamping
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 specifica-
tion 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 speci-
fication.
Tank cars used to transport nonregulated commodities that give off flammable vapors at or below
150 °F (65.6 °C), as determined by Tagliabue’s 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
as follows:
3.3.5.1 If the tank is built in compliance with all requirements of DOT 179.220, it 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.
C-III [M-1002] 64 10/2007

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 specifi-
cation number.
3.4 (AAR.400) Specifications Applicable to Class AAR-207W Pressure Differential Cov-
ered 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 require-
ments.
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-sec-
tion.
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 sepa-
rate entity.
Insulation is not a requirement of this specification.
The minimum required bursting pressure is listed in paragraph 3.4.23 (AAR.401).
10/2007 C-III [M-1002] 65

CHAPTER 3 M-1002

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 M10
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 M10
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 M10
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 M10
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.
3.4.7.1 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 dou-
ble-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 19.3.4.
10/2007 C-III [M-1002] 67

CHAPTER 3 M-1002
3.4.9.3.3 When a radiotape of a longitudinal or circumferential weld does not comply with the
acceptance standards, two additional areas adjacent to the defective welding must be radioscoped.
When the welding and the adjacent areas comply with the acceptance standards, the defective
area must be repaired and radioscoped. 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 must be radio-
scoped.
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 paragraph 6.1.
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 dur-
ing 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.
C-III [M-1002] 68 10/2007

M-1002 CHAPTER 3

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 builder’s 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 fig-
ures at least 1 1/2 in. (38.1 mm) high.
10/2007 C-III [M-1002] 69

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] 70 10/2007

10/2007
M-1002
10/2007
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

(AAR.400-4)] Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional
Bursting Pressure, psi (kPa)

[see paragraph 3.4.5 (AAR.400-5)] 50 (345) 70 (483) 100 (689) 100 (689) 120 (827) 120 (827) 150 (1034) 150 (1034) 200 (1379) 200 (1379)
Minimum Plate Thickness, in. (mm)

[see paragraph 3.4.6 (AAR.400-6)]
Shell—Bottom 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)

[see paragraph 3.4.17 ( AAR.400-17)] 20 (138) 28 (193) 40 (276) 40 (276) 48 (331) 48 (331) 60 (414) 60 (414) 80 (552) 80 (552)
C-III [M-1002] 71
Pressure relief Valve:
Start-to-Discharge Pressure,
psi ±3 psi (kPa range) 15 (82.7 21 (117 30 (186 30 (186 36 (228 36 (228 45 (290 45 (290 60 (393 60 (393
[see paragraph 3.4.16 ( AAR.400-16)] to 124) to 165) to 228) to 228) to 269) to 269) to 331) to 331) to 434) to 434)
Valve Flow Rating Pressure,

psi (kPa) (maximum) 18 (124) 24 (165) 33 (228) 33 (228) 40 (276) 40 (276) 50 (345) 50 (345) 66 (455) 66 (455)
Vapor-Tight Pressure
(minimum) psi (kPa) 12 (83) 17 (117) 24 (165) 24 (165) 29 (200) 29 (200) 36 (248) 36 (248) 48 (331) 48 (331)
Vent Bursting Pressure, Maximum

psi (kPa) [see paragraph 3.4.16
(AAR.400-16)] 15 (103) 21 (145) 30 (207) 30 (207) 36 (248) 36 (248) 45 (310) 45 (310) 60 (414) 60 (414)
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 dis-
charge opening in the top of the tank. The tank may have a bottom outlet opening and may be pro-
vided 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.-thick (6.35-mm) 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 inter-
mediate 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 paragraphs 6.2 and 6.3.
3.5.8.3 See also paragraphs 6.1.2 through 6.1.9 and 5.2.2.
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.
C-III [M-1002] 72 10/2007

M-1002 CHAPTER 3
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.
3.5.11.1 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 clo-
sures 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 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) high 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 builder’s 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.
10/2007 C-III [M-1002] 73

CHAPTER 3 M-1002
C-III [M-1002] 74 10/2007

M-1002 CHAPTER 4
CHAPTER 4
ACCEPTABILITY OF TANK CONTAINERS AND TANK TRAILERS
CONTENTS

4.1 Specifications for Acceptability of Tank Containers (AAR.600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–76
4.1.1 (AAR.600-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–76
4.1.3 (AAR.600-3) Insulation Jacket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–76
4.1.4 (AAR.600-4) Design Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–76
4.1.5 (AAR.600-5) Thickness of Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–77
4.1.7 (AAR.600-7) Tank Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–77
4.1.8 (AAR.600-8) Expansion Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–77
4.1.9 (AAR.600-9) Manway, Nozzles, Flanges, and Other Openings. . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–77
4.1.10 (AAR.600-10) Closures for Manways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–77
4.1.11 (AAR.600-11) Gauging Devices, Top Loading and Unloading Devices, and Air Inlet Devices . . . . C-III–78
4.1.14 (AAR.600-14) Closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–78
4.1.15 (AAR.600-15) Tank Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–79
4.1.16 (AAR.600-16) Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–79
4.1.17 (AAR.600-17) Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–79
4.1.18 (AAR.600-18) Retest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–79
4.1.19 (AAR.600-19) Container Securement System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–79
4.2 (AAR.700) Specifications for Acceptability of Tank Trailers in TOFC Service . . . . . . . . . . . . . . . . . . . C-III–80
10/2007 C-III [M-1002] 75

CHAPTER 4 M-1002
CHAPTER 4. ACCEPTABILITY OF TANK CONTAINERS AND TANK TRAILERS

4.1 Specifications for Acceptability of Tank Containers (AAR.600)
4.1.1.1 Subject to the provisions of 49 CFR 174.63, the following shall apply:
4.1.1.1.1 Tank containers that meet the requirements of this specification may be accepted for
unrestricted interchange movement on conventional single-unit COFC cars equipped with end-of-
car cushioning protection meeting the performance requirements of Chapter 8 of AAR Specifica-
tion M-1001 and with positive-lock securement devices meeting the requirements of AAR Specifi-
cation M-952.
4.1.1.1.2 Tank containers that meet the requirements of this specification may be accepted for
controlled interchange movement on noncushioned single- or multi-unit double-stack cars, multi-
unit spine cars, and other slackless multi-unit intermodal equipment approved under the provi-
sions of Chapter 12 of AAR Specification M-1001. Positive-lock securement devices conforming to
AAR Specification M-952 are required.
4.1.1.2 Unless otherwise permitted herein, tank containers must meet the requirements of one of
the following specifications:
4.1.1.2.1 Specifications for original construction are as follows:
DOT 51 IMO Type 5

DOT 60 IMO Type 7
IM-101 ISO 1496/III
IMO Type 1
4.1.1.2.2 Tank containers designed and constructed to specifications other than those listed are
permitted if approved by the AAR Tank Car Committee.
4.1.1.3 Tank containers carrying regulated commodities are prohibited in TOFC service.
Approval of a tank container is contingent upon the following:
4.1.2.1 Certification attesting to conformance to the specification under which the container was
built. The certification agency must be approved by a competent authority.
4.1.2.2 Manufacturer’s or owner’s certification of compliance with all the requirements of
AAR.600.
4.1.2.3 Prototype tests to the requirements of paragraph 4.1.15 (AAR.600-15).
4.1.3 (AAR.600-3) Insulation Jacket
If insulation is applied, the entire insulation must be covered with a metal or approved equivalent
jacket of a thickness not less than 22 MSG (0.032 in., 0.813 mm), nominal, and flashed all around
so as to be weather tight.
4.1.4 (AAR.600-4) Design Pressure
The minimum design pressure must be not less than that required by 49 CFR or IMDG.
C-III [M-1002] 76 10/2007

M-1002 CHAPTER 4

4.1.5.1 The wall thickness after forming the tank shell and heads, but not including corrosion
allowance, must be not less than the following:
• 1/4- in. (6.35-mm) carbon steel for nonregulated commodities
• 3/8-in. (9.52-mm) carbon steel for placarded commodities and other commodities regulated
by the Department of Transportation
• 8 MSG (0.1644-in., 4.18-mm) austenitic stainless steel for regulated commodities
• 0.118-in. (3-mm) austenitic stainless steel for nonregulated commodities
• 0.224-in. (5.69-mm) ASTM B162 nickel plate material for regulated commodities
• 0.161-in. (4.09-mm) ASTM B162 nickel plate material for non-regulated commodities
4.1.5.2 In no case shall the wall thickness after forming the tank shell and heads be less than
that calculated by the applicable code under which the tank is constructed.
All parts and items of construction in contact with the lading must be compatible with the plate
material and not be subject to rapid deterioration by the lading, or be coated or lined with suitable
corrosion-resistant material. Carbon steels may be clad. Cast irons are prohibited.
4.1.7 (AAR.600-7) Tank Heads
4.1.7.1 All tank heads must be ellipsoidal, hemispherical, or flanged and dished.
4.1.7.2 The voids between compartment heads must be provided with one tapped drain hole at
the lowest point and a tapped and plugged hole at the top of the tank.
4.1.8 (AAR.600-8) Expansion Capacity
4.1.8.1 For liquids other than compressed gases, a minimum outage of 2% of the total capacity of
the tank and manway (or dome if so constructed) must be provided when the container is offered
for transportation by rail.
4.1.8.2 For compressed gases, the maximum permitted filling density is that prescribed in DOT
173.315 (a) through (f).
4.1.9 (AAR.600-9) Manway, Nozzles, Flanges, and Other Openings
4.1.9.1 These attachments must be fusion-welded.
4.1.9.2 Manway ring or flange must be of cast, forged, or fabricated metal of good weldable qual-
ity in conjunction with the materials of the tank or nozzle.
4.1.9.3 Openings for manway and other fittings must be welded and reinforced in the manner
required by the code under which the tank is fabricated.
4.1.10 (AAR.600-10) Closures for Manways
The joint between the manway cover and its seat must be made tight against leakage of vapor and
liquid by use of a gasket of suitable material.
10/2007 C-III [M-1002] 77

CHAPTER 4 M-1002
4.1.11 (AAR.600-11) Gauging Devices, Top Loading and Unloading Devices, and Air
Inlet Devices
4.1.11.1 When installed, the exterior portion of a gauging, top loading, unloading, or air inlet
device must have a protective housing.
4.1.11.2 Protective housing is not required for any device that, in the event of damage, will not
result in loss of lading.
4.1.11.3 Protective housing, if applied, must have a cover and sidewalls not less than 0.119 in.
(3.02 mm) thick for carbon steel material or 0.08 in. (2 mm) thick for stainless steel.
4.1.11.4 Gravity-actuated vacuum relief devices are prohibited.
4.1.11.5 Lead gaskets are prohibited on acid loading covers.
4.1.12.1 A tank may be equipped with a bottom outlet meeting the requirements of the specifica-
tion to which it is constructed. If so equipped, the bottom outlet must be provided with a liquid-
tight closure at its lower end, and the primary outlet valve operating mechanism, if bottom oper-
ated, must be equipped with a positive locking means to ensure closure during transit.
4.1.12.2 Bottom outlets are prohibited on tanks in poison liquid, corrosive liquid, or compressed
gas service unless recessed or protected.
4.1.12.3 Tank containers constructed to IM-101 or IMO-1 specifications that are used to ship non-
regulated food-grade commodities may operate without a self-closing internal shutoff valve on the
bottom opening. Tank containers in this service must be marked AAR600-NR and must have an
external valve with a liquid-tight closure applied at the lower end. Such containers must not be
marked as being in compliance with the IM-101 or IMO-1 specifications.
4.1.13.1 A pressure relief device must be provided and must meet the requirements of the specifi-
cation to which the tank is constructed.
4.1.13.2 Pressure relief device settings must conform to the tank specification, except that the
minimum setting must be based on the design pressure prescribed in paragraph 4.1.4 (AAR.600-
4).
4.1.13.3 Except for corrosive-liquid tanks, pressure relief valves must be flow-rated according to
established procedures.
4.1.13.4 Nonreclosing pressure relief devices (fusible plugs or rupture disc devices) are prohib-
ited.
4.1.14 (AAR.600-14) Closures
All manways and other openings must have closures.
C-III [M-1002] 78 10/2007

M-1002 CHAPTER 4
4.1.15 (AAR.600-15) Tank Mounting

4.1.15.1 Tank must be permanently mounted in a support frame conforming to the specification
under which it was constructed.
4.1.15.2 Frame corner casting dimensions must conform to ISO 1161, Specification of Corner Fit-
tings for Series 1 Freight Containers. Cast-iron corner castings are prohibited.
4.1.15.3 The frame and tank supports must be designed so as not to exceed 80% of the specified
yield strength for 2.0-G vertical loading in combination with 3.5-G longitudinal loading, and for
1.5-G transverse loading combined with 2.0-G vertical loading. Vertical loading in both directions
is to be considered.
4.1.15.4 A prototype tank in its mounting must be certified to the test requirement of ISO 1496/
III, Series 1 Freight Containers—Specification and Testing—Part 3: Tank Containers for Liquids,
Gases, and Pressurized Dry Bulk. In addition, a single prototype tank in its mounting must with-
stand with no visible damage the dynamic longitudinal impact test set out in Appendix E of
National Standards of Canada CAN/CGSB-43.147-2002, “Construction, Modification, Qualifica-
tion, Maintenance, and Selection and Use of Means of Containment for the Handling, Offering for
Transport or Transporting of Dangerous Goods by Rail,” March 2002, published by the Canadian
General Standards Board (CGSB).
4.1.16 (AAR.600-16) Marking
4.1.16.1 A tank conforming to this specification and certified as such must be marked on the
tank, or on the jacket if insulated, on both sides near the right end in 2-in. (50.8-mm) letters as fol-
lows:
•“AAR 600” if qualified for regulated commodities; or
•“AAR 600-NR” if qualified for nonregulated commodities
4.1.16.2 Equipment marks must consist of four alphabetic letters, the last of which must be a “U.”
The Bureau International Des Containers (BIC) or its designated national registration organiza-
tion (NMFTA in the United States) will assign such marks. The stenciled number will consist of
six Arabic numerals in accord with standards established by the International Organization for
Standardization (ISO) and the Association of American Railroads (see Code of Trailer and Con-
tainer Service and Reporting Rules).
All data plates required by the tank specification or by the competent authority must be affixed to
the tank or frame.
4.1.17 (AAR.600-17) Certificate
Prior to offering a tank for transportation, a certificate from the manufacturer or owner affirming
that the tank meets the requirements of this specification and identifying the tank by serial num-
ber and owner must be furnished to the Bureau of Explosives. This certificate must be accompa-
nied by a document attesting to successful tests of a prototype per paragraph 4.1.15.4 [AAR.600-
15(d)], including impact. The tanks must be registered in the Universal Machine Language Equip-
ment Register in the format prescribed in the UMLER Data Specification Manual.
4.1.18 (AAR.600-18) Retest
Tank and pressure relief valve, if installed, must have a retest interval no greater than 5 years.
Retest dates must be marked or stenciled on the tank or on an appropriate plate.
4.1.19 (AAR.600-19) Container Securement System
Tank containers that meet the requirements of this specification will be equipped with provisions
to accept positive securement devices when the tank is used in TOFC or COFC service. The provi-
sion for securement devices will be attached to the container frame or tank support and will be
designed according to the parameters set forth in paragraph 4.1.15.3 [AAR.600-15(c)].
10/2007 C-III [M-1002] 79

CHAPTER 4 M-1002
4.2 (AAR.700) Specifications for Acceptability of Tank Trailers in TOFC Service

See Manual of Standards and Recommended Practices, Section I, Specification M-931, Appendix F.
C-III [M-1002] 80 10/2007

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

5.1 Requirements for Tank and Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–82
5.1.1 Welding Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–82
5.1.2 Heater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–82
5.1.3 Welding Stud Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–83
5.1.4 Plate Thickness and Material Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–83
5.1.5 Openings in Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–84
5.1.6 Placard Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–84
5.1.7 Safety Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–84
5.1.8 Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–84
5.1.9 Lifting Provision Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–84
5.2 Tank Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–84
5.2.1 Anchors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–84
5.2.2 Tank Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
5.3 Head Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
5.3.1 Design and Test Requirements for Head Shield Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
5.4 Auxiliary Compressed Gas Containers on Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
5.4.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
5.4.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
5.4.3 Supply Containers and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–89
5.4.4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–89
5.4.5 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–90
5.4.6 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–90
5.4.7 Engine and Heater Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–91
5.4.8 Vaporizers for Liquefied Gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–91
5.4.9 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–91
10/2007 C-III [M-1002] 81

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 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 compli-
ance 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 thick-
ness of the plate must be not less than the minimum required thickness less allowable ASTM tol-
erances; 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 Material for pressure or vacuum retention portion of tank car tanks 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 visi-
ble. 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 sub-
sequent 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 fin-
ished 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 com-
pleted 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 com-
pliance as provided for in the material specification and must examine those reports and certifi-
cates 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 specifica-
tion designation, including grade, type, and class, if applicable, and each piece is so marked.
10/2007 C-III [M-1002] 83

CHAPTER 5 M-1002
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 per-
mit 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 Rec-
ommended Practices, Section C, Standard S-234. Each design of a tank car lifting provision is sub-
ject 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 mini-
mum 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 cen-
ter of the lifting provision.
5.1.9.3 After application and release of the required load, visual inspection must reveal no evi-
dence 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 12.0. 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
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.
C-III [M-1002] 84 10/2007

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 pur-
poses 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 com-
puted by the following formula. Critical buckling stress (σcr) must be equal to or greater than the
maximum compressive stress in the member (anchor or sill) due to Su. The thickness of the con-
nected elements of the anchor and sill must be not less than 7/16 in. (11.1 mm).
0.076 ( σ u ) 2 ⎛ b ⎞ 2
σ cr = σ u – ----------------------------
- ---
⎝ ⎠
E t
where
σcr = critical buckling stress, psi (MPa)
σu = 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 riv-
ets, 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.
10/2007 C-III [M-1002] 85

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 6.1) 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 Limit—Conventional 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 Limit—SI 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, 50–60 ksi shear ultimate, undriven 63 (434)
Two-piece rivet, 126–157 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 reinforc-
ing plate, the shear strength of the welded connection must be at least equal to the minimum
shear strength required for the anchor fasteners.
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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 secu-
rity. 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 fol-
lowing 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 3 402 000h
Vertical F vertical = W s ⎛ 1 + ------------------------------ ⎞ F vertical = 9.8W s ⎛ 1 + ------------------------------ ⎞
⎝ Wc L ⎠ ⎝ Wc L ⎠
combined with
1,250,000W s 5 560 000W s
Longitudinal F longitudinal = ----------------------------------- F longitudinal = -----------------------------------
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)
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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 attach-
ment 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 two 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 practi-
cal 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 dur-
ing 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, RP-229, “Requirements for Installa-
tion and Use of Liquefied Petroleum Gases on Freight and Passenger Cars.”
5.4.2 Definitions
In addition to the definitions and abbreviations in paragraph 1.2, the following apply in this sec-
tion.
Table 5.3 General definitions
Liquefied compressed gas A gas that, under the charged pressure, is partially liquid at a
temperature of 70 °F (21.1 °C).
Nonliquefied compressed A gas that, under the charged pressure, is entirely gaseous at a
gas temperature of 70 °F (21.1 °C).
Supply container A container that complies with DOT specifications for cargo
tanks, portable tanks, or compressed gas cylinders.
Vaporizer A device used to evaporate liquefied compressed gases, usually
where the required flow rate exceeds the normal flow rate
achieved by natural heat transfer from the atmosphere
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M-1002 CHAPTER 5
5.4.3 Supply Containers and Installation

5.4.3.1 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.
5.4.3.2 Installation
5.4.3.2.1 Supply containers must be mounted on the car, outside of the tank, in a place and man-
ner that will minimize the possibility of mechanical damage.
5.4.3.2.2 Supply containers must be mounted within the limiting outline to which the car is built.
5.4.3.2.3 Suitable shielding or protection must be provided for containers when any portion
extends below the centerline of draft.
5.4.3.2.4 Supply containers must be secured by attachments that will withstand, without perma-
nent 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.
5.4.3.2.5 Welding to the shell, head, or any part of the container is prohibited except when per-
formed by a container manufacturer.
5.4.3.2.6 Metal boxes or shields protecting containers must be painted white and must be sten-
ciled “FLAMMABLE GAS” in letters not less than 1 1/2 in. (38.1 mm) high. When the contents are
nonflammable, the stenciling must be “NONFLAMMABLE GAS” in letters not less than 1 1/2 in.
(38.1 mm) high.
5.4.4 Valves
5.4.4.1 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.
5.4.4.2 An excess flow valve must be installed in a flammable gas supply container outlet connec-
tion 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.
5.4.4.3 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.”
5.4.4.4 Where more than one supply container is installed, a back-flow check valve also must be
installed.
5.4.4.5 The pressure regulating system must consist of one of the following arrangements:
5.4.4.5.1 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.
5.4.4.5.2 A single-stage regulator to control flow of gas from supply container to engine, heater, or
other use.
5.4.4.5.3 A single-unit two-stage regulator to control flow of gas from supply container to engine,
heater, or other use.
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CHAPTER 5 M-1002
5.4.5 Piping
5.4.5.1 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).
5.4.5.2 Aluminum pipe or tubing must not be used.
5.4.5.3 Welded pipe joints must be used wherever possible.
5.4.5.4 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.
5.4.5.5 Cast iron or aluminum fittings are prohibited.
5.4.5.6 Suitable provision must be made to compensate for thermal expansion and contraction.
5.4.5.7 For nonflammable compressed gases, stainless braided PTFE hose may be used.
5.4.6 System
5.4.6.1 All parts of the system must be adequately protected from loose objects propelled from the
roadbed.
5.4.6.2 Container and piping system must be arranged for a single car function. Extension of the
piping system to an adjacent car is not authorized.
5.4.6.3 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.
5.4.6.4 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.
5.4.6.5 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.
5.4.6.6 Pipes, fittings, and accessories must be clamped and fastened to protect them from vibra-
tion, strain, or wear from the usual freight car motions and impacts.
5.4.6.7 A pressure relief valve must be installed between any two shut-off valves or any condition
in the piping where liquid may be trapped.
5.4.6.8 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.
5.4.6.9 Regulating equipment and controls must be protected by metal cabinets or shields to pre-
vent damage or tampering and to give protection from the weather. Car framework may be used
where practical to form part of this shielding.
5.4.6.10 All valves and accessories between the tank and first-stage regulator must have a mini-
mum design pressure of 250 psi (1724 kPa).
C-III [M-1002] 90 10/2007

M-1002 CHAPTER 5
5.4.7 Engine and Heater Fittings

5.4.7.1 Exhaust pipes must be insulated or shielded and positioned to prevent injury to person-
nel.
5.4.7.2 An automatic shut-off device must be provided to shut off the fuel to the gas-air mixer
when the engine is stopped.
5.4.7.3 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.
5.4.8 Vaporizers for Liquefied Gases
5.4.8.1 For liquid withdrawal utilizing a vaporizer, there must be a regulator in accord with
paragraph 5.4.4.5 to control the flow of gas from the fuel container to the engine or heater.
5.4.8.2 Vaporizers must have a minimum design pressure of 250 psi (1724 kPa).
5.4.8.3 Combustion exhaust gases must not be used as a direct means of heat supply for the
vaporization of fuel.
5.4.9 Inspection and Maintenance
5.4.9.1 Inspection and repairs to the system must be made by qualified personnel.
5.4.9.2 The following inspection should be made at time of filling or pre-trip inspection:
5.4.9.2.1 All systems must be visually inspected for loose parts.
5.4.9.2.2 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.
5.4.9.2.3 LP-gas systems must be tested to certify operation of automatic shut-off devices.
5.4.9.3 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 owner’s representative at intervals not longer than the retest period
for the supply container.
5.4.9.4 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.
10/2007 C-III [M-1002] 91

CHAPTER 5 M-1002
C-III [M-1002] 92 10/2007

M-1002 CHAPTER 6
CHAPTER 6
CAR STRUCTURE DESIGN AND TEST REQUIREMENTS
CONTENTS

6.1 Car Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–94
6.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–94
6.1.2 Center Sills or Draft Sills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–94
6.1.3 Body Bolsters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–95
6.1.4 Jacking Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–95
6.1.5 Draft Gears, Draft Attachments, and Cushion Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–95
6.1.6 Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–95
6.1.7 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–95
6.1.8 Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–96
6.1.9 Center of Gravity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–96
6.1.10 Limiting Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–97
6.1.11 Horizontal and Vertical Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–97
6.1.12 Standard Nominal Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–97
6.2 Design Loads and Stresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–97
6.2.1 Vertical Loads on Coupler Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–97
6.2.2 Jacking Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–97
6.2.3 Draft and Compressive End Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–98
6.2.4 Impact Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–98
6.3 Test Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–98
6.3.1 General Test Requirements for Car Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–98
6.3.2 Static Vertical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–98
6.3.3 Jacking Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–98
6.3.4 Static Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–98
6.3.5 Dynamic Squeeze Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–99
6.3.6 Impact Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–99
10/2007 C-III [M-1002] 93

CHAPTER 6 M-1002
CHAPTER 6. CAR STRUCTURE DESIGN AND TEST REQUIREMENTS

6.1 Car Structure
6.1.1 General
Chapters 5, 6, and 7 of AAR Specification M-1001 must be used as a guide in the design, fabrica-
tion, and construction of all components of tank cars. Nonstructural attachments can be exempted
from Chapter 7 upon approval by the Tank Car Committee. The manner in which tanks are
attached to the car structure must be approved.
6.1.2 Center Sills or Draft Sills
6.1.2.1 Structural steel must comply with the current issues of ASTM specifications or other
specifications permitted in AAR Specification M-1001, paragraph 3.1.
6.1.2.2 Rivets must comply with the current issue of ASTM A502, Grade 1.
6.1.2.3 Center sills or draft sills must be equipped with cast steel or forged steel center plates.
Steel castings must comply with the current issue of AAR Specification M-201.
6.1.2.4 The minimum center sill area between points of impact must be 24.24 in.2 (15 639 mm2)
provided the design requirements specified in paragraph 6.2 are met.
6.1.2.5 Draft sills on all tanks cars without continuous center sills must be attached to reinforc-
ing plates that are, in turn, attached to the tank, and the sills must be designed as follows:
6.1.2.5.1 The welds securing the sill to the reinforcing plate must have a total throat area not
exceeding 85% of the total throat area of the reinforcing plate-to-shell welds. These areas may be
modified to use equivalent area values if the welding procedure differs for each weld area under
consideration and also may be modified for parent metal strength considerations. The relative ulti-
mate tensile strength must be used for the calculation of equivalent areas. The minimum strength
of the attachment of the draft sill to the reinforcing pad must comply with the requirements of
paragraph 6.2.
6.1.2.5.2 The reinforcing plates must extend transversely at least 1 in. (25.4 mm) on either side of
the draft sill attachment.
6.1.2.5.3 The termination of the draft sill reinforcing plates must have corner radii not less than
1 in. (24.5 mm), except that a termination on a head must have corner radii not less than 3 in.
(76.2 mm).
6.1.2.6 Center sills must be reinforced at all cutouts outside the anchor area to provide the
moment of inertia, section modulus, and radius of gyration equivalent to the original section and
must be reinforced against local buckling. Within the center anchor area, the sill must either be
reinforced to replace the cross-sectional area of the cutouts or be restored to comply with
paragraph 6.1.2.4. The reinforcement material and its attachment must develop the full required
strength of the center sill. Intermittent welding of the reinforcement is not permitted. Attention
also should be given to the anchor ends and reinforcements to minimize stress concentrations in
the center sill.
Anchor connection plates may be considered as usable reinforcement of the sill when adequately
attached by continuous weld of the proper size in the area of the cutout.
For anchor design requirements, see paragraph 5.2 of this specification and Appendix E,
paragraph 12.0.
6.1.2.7 All cutouts in the center sill that are flame or arc cut must be radiused and finished
smooth, without notches, or must have a welded rim reinforcement applied. See AAR Manual of
Standards and Recommended Practices, Section C-II, Specification M-1001, paragraph 5.1.2, “Cut-
ting.”
C-III [M-1002] 94 10/2007

M-1002 CHAPTER 6
6.1.3 Body Bolsters

6.1.3.1 Body bolsters must be steel, either cast or fabricated. Body bolsters must be designed for
the loading conditions and maximum stresses contained in paragraphs 6.2.2.1 and 6.2.4 of this
specification and paragraph 4.4.13.4 of AAR Specification M-1001.
6.1.3.2 The minimum contact angle subtended by the bolster structure must be not less than
120°, exclusive of the saddle plate. Consideration must be given to the compressive load on the bol-
ster slabbing area, where applicable.
6.1.3.3 The configuration of the bolster must be such that the stress under static load in the tank
shell at the horn of the bolster saddle and at the termination of the saddle plate must not exceed
one-sixth of the minimum tensile strength of the tank material as given in Appendix M. These
stress values must be determined by tests or by other acceptable analytical methods.
6.1.3.4 Bolsters on all tank cars without continuous center sills must be attached to reinforcing
plates that are, in turn, attached to the tank, and the bolsters must be designed as follows:
6.1.3.4.1 The welds securing the bolster to the reinforcing plate must have a total throat area not
exceeding 85% of the total throat area of the reinforcing plate-to-shell welds. These areas may be
modified to use equivalent area values if the welding procedure differs for each weld area under
consideration and also may be modified for parent metal strength considerations. The relative ten-
sile strengths must be used for the calculation of equivalent areas. The design of the bolster must
comply with the requirements of paragraph 6.1.3 and paragraph 6.3.3.1.
6.1.3.4.2 The upper termination of the bolster reinforcing plates must have corner radii not less
than 3 in. (76.2 mm).
6.1.4 Jacking Pads
Provision must be made for jacking under bolsters or at an approved alternate location when
required by car design.
6.1.5 Draft Gears, Draft Attachments, and Cushion Devices
Draft gears, draft attachments, and cushion devices must comply with Section B of the AAR Man-
ual of Standards and Recommended Practices, except where superseded by AAR Specification
M-1001.
6.1.6 Couplers
6.1.6.1 Couplers must comply with the AAR Manual of Standards and Recommended Practices,
Section B, except where superseded by AAR Specification M-1001 or by the Field Manual of the
AAR Interchange Rules.
6.1.6.2 Couplers on DOT specification cars must comply with DOT 179.14.
6.1.6.2.1 All tank cars carrying regulated commodities must be equipped with top-and-bottom
shelf couplers. All tank cars carrying nonregulated commodities must have couplers replaced with
top-and-bottom shelf couplers at the next coupler replacement cycle.
6.1.7 Brakes
Brakes, including badge plates, must comply with Section E of the AAR Manual of Standards and
Recommended Practices, except where superseded by AAR Specification M-1001.
10/2007 C-III [M-1002] 95

CHAPTER 6 M-1002
6.1.8 Trucks
6.1.8.1 Trucks must comply with the AAR Manual of Standards and Recommended Practices,
Section D.
6.1.8.2 Block-type side bearings are prohibited on tank cars ordered built new after December 31,
2001. Side bearings on tank cars ordered built new after December 31, 2001, must conform to the
nominal 5 1/16-in. side bearing height per AAR Manual of Standards and Recommended Practices,
Section D, Specification M-948.
6.1.9 Center of Gravity
6.1.9.1 The center of gravity of the loaded car must be reported on the Certificate of Construction
and must not exceed 98 in. (2489 mm).
6.1.9.2 When computing the center of gravity, the factors for the arms must be as follows:
6.1.9.2.1 Trucks
Trucks based on an arm equal to the distance from top of rail to centerline of axle.
6.1.9.2.2 Underframe
Underframe based on an arm equal to the distance from top of rail to centerline of draft, less
amount of spring deflection as shown in Table 6.1. For trucks having spring deflection not shown,
use the deflection corresponding to that caused by gross rail load.
Table 6.1 Spring deflection
Spring Travel Spring Deflection
Spring
in. mm in. mm
D-2* 1 5/8 41.3 3/4 19.0
D-3 2 1/2 63.5 1 1/4 31.8
D-4 3 1/16 77.8 1 3/8 34.9
D-5 3 11/16 93.7 1 5/8 41.3
D-7 4 1/4 108.0 1 7/8 47.6
* For reference only on cars built prior to January 1, 1956.
6.1.9.2.3 Tank
• The weight (mass) of the tank must include the connections, insulation, and other attach-
ments.
• The moment arm calculations must take into consideration the spring deflection (see Table
6.1).
• For cylindrical tanks, the moment arm must be measured from the center of the tank.
• For noncylindrical tanks, the moment arm must be determined by a method that takes
such geometry into effect.
C-III [M-1002] 96 10/2007

M-1002 CHAPTER 6
6.1.9.2.4 Lading
• The weight (mass) of the lading must be the difference between the rail load limit and the
light weight (tare).
• The moment arm calculations must take into consideration the spring deflection (see Table
6.1).
• For cylindrical tanks with an expansion dome, the moment arm must be the same as that
used for the tank.
• For cylindrical tanks without an expansion dome, the moment arm must be 3/4 in. less
than that used for the tank.
• For noncylindrical tanks, the moment arm must be determined by a method that takes
such geometry into account.
6.1.10 Limiting Outline
The limiting outline of cars must comply with AAR Specification M-1001, paragraph 2.1.2.
6.1.11 Horizontal and Vertical Curves
6.1.11.1 Tank cars must be designed to operate over horizontal and vertical curves in accord with
the requirements of AAR Specification M-1001, paragraph 2.1.4.
6.1.11.2 Extreme projections of appurtenances at centerline of car must have a minimum rail
clearance in accord with Appendix E.
6.1.12 Standard Nominal Dimensions
Standard nominal dimensions must comply with AAR Specification M-1001, paragraph 2.1.
6.2 Design Loads and Stresses
6.2.1 Vertical Loads on Coupler Head
The car structure must be designed to withstand a 50,000-lb (222.4-kN) vertical load, applied in
both directions on the coupler head at the pulling face, without yielding the loaded members or
exceeding their critical buckling strengths.
6.2.2 Jacking Load
6.2.2.1 The car structure must be designed to withstand the weight (mass) of the car when loaded
to its rail load limit and supported at the jacking pad locations, without yielding the loaded mem-
bers or exceeding their critical buckling strengths.
6.2.2.2 The car structure of a stub sill car must be designed to withstand a vertical upward load
applied to the coupler shank between the coupler horn and striker at one end of the car, sufficient
in magnitude to lift the fully loaded car free of the truck nearest the applied load, without yielding
the loaded members or exceeding their critical buckling strengths. Cars with continuous center
sills are excluded from the requirements of this paragraph.
10/2007 C-III [M-1002] 97

CHAPTER 6 M-1002
6.2.3 Draft and Compressive End Loads

6.2.3.1 For cars with or without continuous center sills, the car structure (including tank shell)
and draft attachments must be designed so that, under the most severe combination of dead and
live loads and a 350,000-lb (1557-kN) draft load, the induced primary plus secondary stresses do
not exceed the yield or critical buckling stresses of the loaded members divided by 1.8; and, under
the most severe combination of dead and live load, including a 15-psi (103-kPa) external pressure,
if applicable, and a 1,000,000-lb (4448-kN) compressive end load, the induced primary plus second-
ary stresses do not exceed the yield or critical buckling stresses of the loaded members. The com-
pressive end load must be applied at the rear draft lugs at each end of car on the nominal
centerline of couplers. For cars without continuous center sills, attention must be directed to the
critical areas at the termination of the stub sill and the stub sill reinforcing plate. In these critical
areas, the flexibilities of the mating structures must be considered to arrive at a realistic struc-
tural model.
6.2.3.2 In addition, for carbon or alloy steel tanks without continuous center sills, the primary
stress in the bottom center of the tank under the combined loadings of loaded tank weight (mass),
internal pressure at the pressure relief device set pressure, and 350,000-lb (1557-kN) tensile end
load applied on the nominal centerline of couplers shall not exceed the minimum tensile strength
of the tank material as given in Appendix M divided by 3.7. This requirement shall not apply when
retrofitting existing cars with pressure relief devices having a set pressure up to 33% of burst pres-
sure.
6.2.4 Impact Load
Design requirements for impact loads and stresses must comply with AAR Specification M-1001,
paragraph 4.1.10.
6.3 Test Requirements
6.3.1 General Test Requirements for Car Structure
New and untried designs must be tested in accordance with this section to show compliance with
the requirements of paragraph 6.2.
6.3.2 Static Vertical Test
A 50,000-lb (222.4-kN) vertical load must be applied in both directions to the coupler head as near
the pulling face as practicable and held for 60 seconds. Strains, when strain gauges are used, and
loads must be recorded.
6.3.3 Jacking Test
6.3.3.1 The test car must be loaded to at least its rail load limit, and one end of the car must be
jacked at the ends of the body bolster or at other approved jacking locations until it is raised off of
the truck.
6.3.3.2 On stub sill cars, a vertical upward load must be applied to the coupler shank between the
coupler horn and striker at one end of the car, sufficient in magnitude to lift the fully loaded car
free of the truck nearest the applied load, and held for 60 seconds. Cars with continuous center
sills are excluded from the requirements of this paragraph.
6.3.4 Static Compression Test
A horizontal compressive end load of 1,000,000 lb (4448 kN) must be applied on centerline of draft
at the rear draft lugs and held for 60 seconds. Draft gears may be removed from the test car for the
static tests. Strains and compressive end loads are to be recorded to show compliance with
paragraph 6.2.3.1. Strain gauges are to be located at critical locations selected by the car builder.
C-III [M-1002] 98 10/2007

M-1002 CHAPTER 6
6.3.5 Dynamic Squeeze Test

This test is optional by the car builder but mandatory when requested by the Equipment Engi-
neering Committee. An impact test may be performed using a minimum of three cars backing up
the test car and four impacting cars, each loaded to a minimum rail load of 177,000 lb (80 286 kg).
The brakes must be set on all standing cars after all slack between cars has been eliminated.
There must be no precompression of the draft gears. The standing cars must be on level tangent
tracks. The striking cars, coupled together, must be used to provide repeated impacts. After each
impact, the standing cars must be adjusted, if necessary, to restore the original condition. A series
of impacts must be made at increments of 2 mph (3.22 km/h) until a coupler force of 1,250,000 lb
(5560 kN) has been reached. A visual inspection of the test car must be made during and after
each of the tests. Any permanent damage requiring shopping of the car for repairs will be suffi-
cient cause for disapproval of the design. If requested by the Equipment Engineering Committee,
strain gauges are to be applied at critical locations and strains recorded during the test. Critical
locations are to be determined by stress coating or other approved method. Coupler forces and
impact speeds must be recorded.
6.3.6 Impact Test
The test car must be loaded to at least the rail load limit for the number and size of axles used
under the car and must be equipped with the draft gear or cushioning device for which the car was
designed. All cars other than the test car must be equipped with draft gears meeting the require-
ments of AAR Specification M-901, and either the struck or striking car must be equipped with an
approved means for measuring coupler force. The test car must be impacted by a car of 70-ton
nominal capacity, loaded to the allowable gross weight on rails prescribed in AAR Specification
M-1001, paragraph 2.1.5.17, in increments of 2 mph (3.22 km/h), until a coupler force of
1,250,000 lb (5560 kN) has been reached. The impacting car should be loaded with a high-density
material to provide a low center of gravity braced to prevent shifting. A visual inspection of the
test car must be made during and after each of the tests. Any permanent damage requiring shop-
ping of the car for repairs will be sufficient cause for disapproval of the design. If requested by the
Equipment Engineering Committee, strain gauges are to be applied at critical locations and
strains recorded during the test. Critical locations are to be determined by stress coating or other
approved method. Coupler forces and impact speeds must be recorded.
10/2007 C-III [M-1002] 99

CHAPTER 6 M-1002
C-III [M-1002] 100 10/2007

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

1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–103
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–103
1.2 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–103
1.3 Service Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–104
2.0 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–105
3.0 Specifications for Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–108
3.1 Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–108
3.2 Nonmetallic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–108
3.3 Stem Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–109
3.4 Cast Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–109
4.0 Specifications for Design and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–110
4.1 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–110
4.2 Pressure Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–110
4.3 Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–110
4.4 Valve Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–111
4.5 Aspiration of Liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–111
4.6 Resetting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–111
4.7 Rupture Disc Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–111
4.8 Combination Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–111
4.9 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–112
4.10 Vacuum Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–112
4.11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–112
4.12 Sampling Line Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–112
4.13 Electrical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–112
4.14 Pneumatic Valve Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–113
4.15 Bottom Outlet Valve Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–113
4.16 Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–113
4.17 Internal Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–113
4.18 Ball Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–114
4.19 Gauging Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–114
5.0 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–114
5.1 Set Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–114
5.2 Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–114
5.3 Rupture Discs Used in Rupture Disc Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–114
5.4 Qualification of Rupture Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–114
5.5 Breaking Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–115
10/2007 C-III [M-1002] 101

APPENDIX A M-1002

5.6 Qualification of Surge Suppression Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–115
6.0 Flow Capacity Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–115
6.1 Test Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–115
6.2 Flow Rating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–115
6.3 Test Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–116
7.0 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–117
7.1 Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–117
7.2 Rupture Disc Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–117
7.3 Liquid and Vapor Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–117
7.4 Liquid Level Control and Gauging Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–118
8.0 Formula for Flow Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–118
8.1 Tank Cars without an Inner Container Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–118
8.2 Tank Cars with an Inner Container Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–120
9.0 Derivation of Formula for Flow Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–121
9.1 Derivation of Equation 8.2.1 and Equation 8.2.2—Conventional Units . . . . . . . . . . . . . . . . . . . . . C-III–125
C-III [M-1002] 102 10/2007

M-1002 APPENDIX A
APPENDIX A
TANK CAR VALVES AND FITTINGS
1.0 INTRODUCTION
1.1 Scope
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
1.2 Approvals
1.2.1 Approval of Valves and Fittings
Tank car valves and fittings must be approved by the Tank Car Committee. Approvals of valves
and fittings must be renewed every 10 years.
1.2.1.1 For pressure relief device approval procedures, see Chapter 1, paragraph 1.4.5, including
Form AAR 4-3 Application for Approval of Pressure Relief Device.
1.2.1.2 For other valves and fittings approval procedures, see Chapter 1, paragraph 1.4.6, includ-
ing Form AAR 4-5 Application for Approval of Valves and Fittings.
1.2.1.3 For renewal of previously approved valves and fittings, as well as changes in these
devices, see Chapter 1, paragraph 1.4.7 requiring submittal of Form AAR 4-7 Application for
Renewal of Approval for Valves and Fittings.
1.2.1.4 All valves and fittings currently considered as approved, either directly or indirectly, must
be submitted for renewal at 10 years from the latest current approval.
1.2.1.5 Previously approved valves and fittings 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 tanks cars without reapproval. Valves and fittings for which the cur-
rent approval has lapsed may be submitted for reapproval per paragraph 1.2.1.3 above.
1.2.1.6 The following are devices that may not require submission to the Tank Car Committee:
• External changes to previously approved devices
• Changes in materials that do not affect the operation of the device
• Changes in materials that are compatible with the intended commodity service
• 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 paragraph 6.1 of this
appendix.
10/2007 C-III [M-1002] 103

APPENDIX A M-1002
1.2.2 Approval of Closures

Tank car closures do not require Tank Car Committee approval if they are manufactured in accor-
dance with a nationally recognized standard (e.g., AAR, SAE, ASME, ANSI, MIL), except the Tank
Car Committee may, at its discretion, require approval of any special closure design. Closures that
require approval must be renewed every 10 years. This paragraph applies to closures on new cars
ordered after, and to closures replaced on existing cars after March 1, 2001.
1.2.2.1 With the exception of valve outlet closures, the Tank Car Committee shall approve all clo-
sures via the approval processes specified in paragraphs 1.2.2.3 and 1.2.2.4 below, unless the man-
ufacture of such closures is in accordance with a nationally recognized standard (e.g., AAR, SAE,
ASME, ANSI, MIL). The Tank Car Committee also shall approve any modification to a bottom out-
let closure as defined in Appendix E, Figs. E24.1 through E24.9.
1.2.2.2 The Tank Car Committee may require approval of any closure design on any class of car.
Closures that require approval must be renewed every 10 years.
1.2.2.3 See paragraph 1.2.1.2 above for approval procedures.
1.2.2.4 See paragraph 1.2.1.3 above for renewal procedures.
1.3 Service Trials
1.3.1 All new devices within the scope of this appendix must be subjected to service trials before
they can be given committee approval. Service trials, when required by the Tank Car Committee,
must be reported semiannually on Form AAR 4-4 in accord with the procedure outlined in Chapter
1, paragraph 1.4.8. The service trial may be waived by the Tank Car Committee, provided the
device meets the conditions specified in paragraph 1.2.1.6 above.
1.3.2 The guidelines for acceptance of valves and fittings by the Tank Car Committee as a result
of service trials are as follows:
1.3.2.1 For nonregulated commodities, each car set of the device must be subjected to a trial of
1 year minimum duration covering an average of 5,000 loaded miles or an average of 10 loaded
trips or load/unload cycles.
For regulated commodities, each car set of the device must be subjected to a trial of 2 years mini-
mum duration covering an average of 10,000 loaded miles or an average of 20 loaded trips or load/
unload cycles. Completion of 1 year, 5,000 loaded miles, and 10 load cycles in regulated commodity
service may be used to qualify the device for nonregulated service.
1.3.2.2 Difficulties experienced during the service trial (e.g., leakage, breakage, or performance
problems) must be reported for review by the Tank Car Committee on Form AAR 4-4, together
with a statement of design revisions to improve operation or to correct the defect.
1.3.2.3 The service trial also must include a Form AAR 4-6 Final Product Test and Inspection
Report to be submitted to the Tank Car Committee at the conclusion of the specified service trial.
1.3.2.4 The Tank Car Committee may request additional tests to supplement the manufacturer’s
tests or service trials prior to acceptance of the device.
1.3.2.5 Approval of a device for a commodity or commodity type does not provide for blanket
approval of the device. Additional data must be submitted to confirm that the device is compatible
with other commodities, including consideration of corrosion or stress corrosion cracking where
appropriate. Commodity types are as follows:
• Compressed gases
• Corrosives
• Solids requiring heat to liquefy
• Free-flowing liquids (general service)
• Products with special temperature requirements
C-III [M-1002] 104 10/2007
M-1002 APPENDIX A
1.3.2.6 Sample size and number of units subject to post-trial teardown are shown in Table A1.
Table A1. Service trial parameters

Minimum Minimum Subject to
Device
Sample Size Post-Trial Teardown
Pressure relief valve or bottom outlet valve 25 5
Top valve or excess flow valve 15 3
Sample line valve, gauging device, or vacuum relief device 10 2
Thermometer well or auxiliary fitting 5 0
2.0 DEFINITIONS
In addition to the definitions and abbreviations in Chapter 1, paragraph 1.2, the following apply in
this appendix:
Table A2. General definitions (page 1 of 3)

Approach channel The passage through which the fluid must pass to reach the oper-
ating parts of a pressure relief device.
Atmospheric pressure Atmosphere pressure equals 14.696 psia (101.325 kPa [abs.]).
Bottom washout A plugged and flanged opening in the bottom of a tank to facilitate
cleaning of a car that 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 and that is designed to break in tension at a
load caused by a predetermined pressure.
Breather vent A device having an operating part that is a permeable disc or a
disc having a breather hole or slit.
Burst pressure The value of the inlet static pressure at which a rupture disc
device or breaking pin device functions.
Check valve A valve that automatically closes to stop the flow of liquid or vapor
in one direction.
Closing pressure The pressure, measured at the valve inlet, at which the valve
closes, flow is substantially shut off, and there is no measurable
lift.
Closure A device that closes an opening into the tank or an auxiliary
device that closes an outlet/inlet connection on a valve or fitting.
Examples include pipe plugs, quick-disconnect caps, blind flanges,
manway covers, outlet caps, eduction pipe caps, and fill hole cov-
ers. When approval is required per paragraph 1.2.2 above, clo-
sures shall be treated as fittings.
Combination device (a) A breaking pin in combination with a pressure relief valve, in
which the breaking pin 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.
Discharge channel The passage through which the fluid must pass beyond the operat-
ing parts of a pressure relief device. This includes all piping or
exhaust flue, screen, and weather covering that may be applied on
the housing.
10/2007 C-III [M-1002] 105

APPENDIX A M-1002

Discharge flow The ratio of the actual flow to the flow of an ideal conduit with the
coefficient same orifice area.
Equipment, explosion- Apparatus enclosed in a case that is capable of withstanding an
proof explosion of a 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, Equipment and wiring that is incapable of releasing sufficient
intrinsically safe electrical or thermal energy under normal or abnormal conditions
to cause ignition of a specific hazardous atmospheric mixture in
its most easily ignited concentration.
Flow capacity Flow capacity of a pressure relief device is the capacity in cubic
feet per minute (cubic meters per second) of air at standard condi-
tions when tested at the required flow rating pressure.
Flow rating pressure The inlet static pressure at which the relieving capacity of a pres-
sure relief device is measured for rating purposes.
Fusible plug device A nonreclosing pressure relief device designed to function by
yielding or melting of a plug of suitable material.
Gauging device A system that furnishes an indication of the liquid level inside a
tank.
Huddle chamber The configuration of the valve body seat and the immediately
adjacent downstream parts that redirect the flow of the effluent,
causing a popping action by lifting the valve stem.
Liquid level control An automatic system that generates a signal to open or close
device valves at a predetermined level.
Liquid tight All closures, except pressure relief valves, are designed to meet
the test pressure of the tank without leakage. All final closures
must show no leakage at loading conditions and during transpor-
tation.
Liquid valve Any valve that is opened and closed manually or automatically to
permit the passage of liquid into or out of the tank.
Pressure relief device A device that is designed to prevent the rise of internal pressure
in excess of a specified value resulting from exposure to abnormal
conditions. “Pressure relief device” is synonymous with the expres-
sion “safety relief device.”
Pressure relief valve A spring-loaded device, actuated by inlet static pressure, that
relieves excess pressure and recloses after normal conditions are
restored.
Rupture disc The operating part of a rupture disc device.
Rupture disc device Consisting of a rupture disc and a rupture disc holder, a nonreclos-
ing pressure relief device actuated by inlet static pressure and
designed to function by bursting of a pressure-containing disc.
Seat That part of the pressure relief valve in its orifice area that forms
a seal with the stem and adjacent parts.
Set pressure The pressure, measured at the valve inlet, at which a pressure
relief valve is set for start-to-discharge.
Standard conditions 60 °F (15.56 °C) and 14.696 psia (101.325 kPa [abs.]).
C-III [M-1002] 106 10/2007

M-1002 APPENDIX A

Start-to-discharge The pressure, measured at the valve inlet, at which there is a
pressure measurable lift of the 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 relieved fluid is first detected at the down-
stream side of the seat.
Surface area (a) The tank surface area of a single-unit, single-compartment
tank car tank is the 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.
(b) 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.
Surge pressure A device incorporated into the design of a tank car or attached
reduction device thereto that, by design, reduces the internal surge pressures at
the pressure relief device interface.
Temperature sensing A part or parts that permit the determination of the temperature
equipment of a tank’s contents.
Vacuum relief valve A pressure relief device designed to admit air to prevent an exces-
sive internal vacuum and to reclose after normal conditions have
been restored.
Valve stem A central movable shaft attached to an integral head or multiple-
piece assembly that contains pressure at the orifice of a pressure
relief valve.
Valves and fittings Those appurtenances, including secondary valves, attached to a
tank car tank by bolting, threading, or welding, designed to con-
trol flow of fluids into and out of the tank; 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. Valves and fittings require Tank
Car Committee approval using procedures in M-1002, Chapter 1,
paragraph 1.4 and in Appendix A. Those nozzles and mountings
welded directly to the tank to mount fittings are not defined as
fittings themselves. Closures, such as blind flanges, caps, and
plugs, are not fittings.
Vapor-tight pressure The pressure, measured at the valve inlet after closing, at which
no further fluid flow is detected at the downstream side of the seat
of a pressure relief valve.
Vapor valve Any valve that is opened or closed manually or automatically to
permit the passage of vapor into or out of the tank.
10/2007 C-III [M-1002] 107

APPENDIX A M-1002
3.0 SPECIFICATIONS FOR MATERIALS

3.1 Metals
All devices covered by this appendix must be fabricated from materials that are resistant to corro-
sive or solvent action of the lading in the liquid or gas phase and are suitable for the service tem-
perature.
3.2 Nonmetallic Materials
Cars Built to
All Other
Non-Regulated Flammable Specified 49 CFR
Regulated
Commodities Liquids Corrosives Subpart C
Commodities
(Pressure Cars)
Primary Prohibited Prohibited Allowed Prohibited Prohibited
Closures See
paragraphs 3.2.1
and 3.2.4
Secondary Allowed Prohibited Allowed Allowed Prohibited
Closures See See See
paragraphs 3.2.2, paragraphs 3.2.2 paragraphs 3.2.2,
3.2.3, 3.2.4, and 3.2.5 and 3.2.4 3.2.3, 3.2.4, and 3.2.5
Gaskets, See See See See See
O-Rings, paragraph 3.2.4 paragraph 3.2.4 paragraph 3.2.4 paragraph 3.2.4 paragraph 3.2.4
and Seals
3.2.1 Except for components that are used in aluminum sulfate, ammonium chloride, ferric chlo-
ride, 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 require-
ments of paragraph 3.2.4 are met. Nonmetallic rupture disc devices may be used as primary clo-
sures, provided they meet the requirements of paragraphs 3.2.4 and 3.2.5.
3.2.2 Nonmetallic material may be used for any secondary pressure-containing parts of any
device covered by this appendix, provided the requirements of paragraphs 3.2.4 and 3.2.5 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 non-
metallic 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. E18 through E18.3 (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 3.2.5. 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.
3.2.3 For newly designed metallic pressure retaining components or devices, the use of nonmetal-
lic 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.
3.2.4 It is the shipper’s responsibility to ensure that all nonmetallic materials are compatible
with the lading and the service temperature.
C-III [M-1002] 108 10/2007

M-1002 APPENDIX A
3.2.5 When required in paragraphs 3.2.1 and 3.2.2, components manufactured of nonmetallic
materials (including design changes to existing devices) must be tested in a manner that is repre-
sentative 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 follow-
ing:
• Pressure Identification Test—Each 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 or a higher temperature as determined by the manufacturer,
and –30 °F.
• Torque Testing—When 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 or a higher temperature as deter-
mined by the manufacturer, and –30 °F.
• Product Compatibility Test—Representative 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 stan-
dard.
• Life expectancy—The life expectancy of the component shall be determined by the compo-
nent manufacturer. Consideration should be given to but not be limited to the results of
UV exposure test under maximum expected atmospheric conditions, expansion and con-
traction, creep, and all of paragraph 3.2 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 produc-
tion parts are physically identical, within established tolerances, to the parts that were qualifica-
tion tested.
3.2.6 The manufacturer of nonmetallic components used in a device or the manufacturer of non-
metallic devices is subject to the facility registration and quality assurance requirements of
paragraph 3.4 of Appendix B.
3.3 Stem Materials
Stem materials for pressure relief valves set at 75 psig (517 kPa) or more must comply with the fol-
lowing requirements:
3.3.1 No “free machining” metal (i.e., having more than 0.07% sulfur, lead, phosphorus, bismuth,
or selenium) may be used.
3.3.2 Cold drawn materials may not be used, unless the stresses due to cold working have been
relieved.
3.3.3 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 assem-
bly is attached, whichever is lower.
3.3.4 No part or whole assembly may be made from cast materials.
3.4 Cast Materials
Cast materials for valves and fittings normally in contact with the lading are restricted to those
listed in Appendix M.
10/2007 C-III [M-1002] 109

APPENDIX A M-1002
4.0 SPECIFICATIONS FOR DESIGN AND APPLICATION

4.1 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 8.2.2 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 capac-
ity of the valve.
4.2 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.
4.3 Design Considerations
4.3.1 Pressure relief devices must be so designed and constructed that the failure of any part can-
not reduce the flow capacity of the device.
4.3.2 Maximum allowable stress in unthreaded sections of stems must be 50% of the yield stress.
4.3.3 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.
4.3.4 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.
4.3.5 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.
4.3.6 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. E19 through E19.9,
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. E19.24.
4.3.6.1 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)].
4.3.6.2 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.
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 15.6 must
be followed.
4.3.7 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 man-
way cover is swung to the full open position.
C-III [M-1002] 110 10/2007

M-1002 APPENDIX A
4.3.8 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 alter-
ation or conversion, the following applies:
4.3.8.1 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-discon-
nect 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.
4.3.8.2 Primary closures (access to tank) must have seal provision. Vacuum relief valves are
exempt from this sealing requirement.
4.3.8.3 Operating valves and fittings must have provision for sealing the operating mechanism or
be enclosed in a protective housing with seal provision.
4.3.8.4 Protection of rupture disc devices may be provided by weather covers with seal provision.
4.4 Valve Configuration
The configuration of a valve and its components must minimize the possibility of trapping and col-
lecting dirt or residue, which adversely affect the operation of the valve.
4.5 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.
4.6 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 pres-
sure. 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 manufacturer’s permission).
4.7 Rupture Disc Device
4.7.1 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.
4.7.2 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.
4.7.3 When a rupture disc device is used, means for inspection of the top portion of the disc with-
out releasing clamping pressure on the disc must be provided.
4.7.4 Tank cars ordered built, converted, or rebuilt after May 1, 1994, that are equipped with rup-
ture disc devices and are placed in regulated commodity service must be equipped with a surge
pressure reduction device.
4.8 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.
10/2007 C-III [M-1002] 111
APPENDIX A M-1002
4.9 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.
4.10 Vacuum Relief Valve
4.10.1 Gravity-actuated vacuum relief valves must not be applied or replaced in kind.
4.10.2 Vacuum relief valves must be designed to seal bubble-tight down to the set negative pres-
sure (typically 0.75 psi [5.17 kPa]) 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.
4.11 Maintenance
4.11.1 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 manufacturer’s permission, except as listed below.
4.11.2 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.
4.12 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.
4.13 Electrical Devices
4.13.1 Electrical Requirements
4.13.1.1 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 com-
pressed gas, or an oxidizing material. Intrinsically safe electrical devices must conform to Under-
writers’ Laboratories Standard No. 913 or Factory Mutual Standard No. FM-3610/3611.
4.13.1.2 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 con-
nection 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 pow-
ered 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.
C-III [M-1002] 112 10/2007

M-1002 APPENDIX A
4.13.2 Environmental Requirements

4.13.2.1 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 per-
form 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.
4.13.2.2 A car-mounted electrical device must operate normally and within its rated accuracy fol-
lowing 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.
lowing 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.
lowing a thermal shock of the magnitude encountered in unloading and loading commodities in
which the device is used.
4.13.2.5 A car-mounted electrical device must operate normally and within its rated accuracy
during normal environmental variations.
4.13.3 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.
4.14 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.
4.15 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 8.0, 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.
4.16 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. E25.1 through
E25.12, 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. of insulation and two-board platforms.
4.17 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.
10/2007 C-III [M-1002] 113

APPENDIX A M-1002
4.18 Ball Valves

Screwed-end ball valves of the external wrenching tailpiece type must not be used unless the tail-
piece is secured to the adjacent body in accord with the valve manufacturer’s recommendations.
Valves of this type without secured tailpiece must be replaced with AAR-approved valves or modi-
fied per manufacturer’s recommendations at next car shopping, but no later than July 1, 2012.
4.19 Gauging Devices
4.19.1 Each manufacturer of gauging devices or components shall make installation, mainte-
nance, and operating instructions available for each device or component.
4.19.2 It is the car owner's 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.
5.0 PRESSURE SETTINGS
5.1 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.
5.2 Tolerance
5.2.1 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 cer-
tifying that test results were within these start-to-discharge tolerances and regulatory vapor-tight
requirements. Use of the Certificate of Test Form (see Fig. D4) is not required for such documenta-
tion.
5.2.2 The permissible tolerance for the burst pressure of a rupture disc must be +0% to –15%.
5.2.3 The permissible tolerance for the burst pressure of a breaking pin must be ±15 psi
(±103 kPa).
5.3 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 5.2.2 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.
5.4 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 dura-
tion of each cycle must not exceed 5 seconds. After cycling the disc, it must be subjected to a pres-
sure 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 pres-
sure tolerance.
C-III [M-1002] 114 10/2007

M-1002 APPENDIX A
5.5 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 5.2.3 above is
exceeded, two more pins must be tested and both must meet specifications or the lot must be
rejected.
5.6 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 man-
ufacturer 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-, 3-, 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.
6.0 FLOW CAPACITY TESTS
6.1 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 rat-
ing 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)
6.2 Flow Rating Test
6.2.1 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, person-
nel, 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.
6.2.2 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 corre-
sponding valves without such devices.
6.2.3 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.
6.2.4 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 rat-
ing 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.
10/2007 C-III [M-1002] 115

APPENDIX A M-1002
6.2.5 After December 31, 2004, the flow capacity of a rupture disc pressure relief system must be
determined as specified in paragraphs 6.2.5.1 through 6.2.5.4. This applies to new construction or
alterations to add a rupture disc device. The flow capacity must be determined for each pressure
setting.
6.2.5.1 Each manufacturer must test the flow capacity of a rupture disc device as an ideal con-
duit, 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 6.2.1) is not required.
6.2.5.2 The flow capacity derived from paragraph 6.2.5.1 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 6.2.5.1 apply. The rated capacity obtained is applicable only to that device and that rup-
ture disc design.
6.2.5.3 When installing surge suppression devices, the flow capacity derived from
paragraph 6.2.5.2 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 5.6. This is the rated flow capacity of the pressure relief system.
6.2.5.4 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.
6.2.6 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.
6.3 Test Reports
6.3.1 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.
6.3.2 The official flow capacity of a device established under paragraph 6.2.4 above must be taken
as the average of tests of three devices of the same design, size, and pressure setting.
6.3.3 The official flow capacity of a rupture disc device is the smallest capacity of the devices
tested, as determined in paragraph 6.2.5 above.
6.3.4 Flow rating, materials of construction, general arrangement, and assembly data in suffi-
cient 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.
C-III [M-1002] 116 10/2007

M-1002 APPENDIX A
7.0 MARKING
7.1 Pressure Relief Valves
7.1.1 Each pressure relief valve must be plainly and permanently marked by the valve manufac-
turer or reconditioner with the required data.
7.1.2 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
• Manufacturer’s 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)
• Month and year of manufacture or retest
7.2 Rupture Disc Devices
7.2.1 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 rup-
ture disc must be marked to indicate the following:
• Burst pressure, psi (or psi and kPa)
• The lot number
7.2.2 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 manufacturer’s design or type number and the serial number
• The flow rating pressure, psi (or psi and kPa)
7.2.3 On discs for which orientation in holder is important, mark “TOP” on discharge side.
7.3 Liquid and Vapor Valves
7.3.1 All valves with a net free-flow area of more than 1/2 in.2 (323 mm2) must be marked to indi-
cate the following:
• Type of trim
• Pressure-temperature limitations
7.3.2 All pressure-retaining valve body castings shall be marked in accordance with the appropri-
ate 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.
7.3.3 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.
7.3.4 Marking requirements of paragraphs 7.3.2 and 7.3.3 above become effective for castings
manufactured after December 1, 2001.
10/2007 C-III [M-1002] 117

APPENDIX A M-1002
7.4 Liquid Level Control and Gauging Devices

7.4.1 Each device must be marked to indicate the following:
• Pressure rating
7.4.2 For all gauging devices, when removed from a car, each separable component that affects
gauging accuracy must be identified to ensure proper reinstallation.
7.4.3 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.
8.0 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:
8.1 Tank Cars without an Inner Container Tank
8.1.1 Conventional Units
0.82
633,000FA ZT Equation 8.1.1a
Q a = ------------------------------------ -------
LC M
0.82
Qa = Gu A (for F=1, see Table A6) Equation 8.1.1b
0.82
Q a = 2G i UA (for F<1, see Table A6) Equation 8.1.1 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 A5)
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:
8U ( 1,200 – t )
F = ----------------------------------
34,500 Equation 8.1.1 d
Gi = the gas factor for insulated containers (see Table A6)
Gu = the gas factor for noninsulated containers (see Table A6)
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.
C-III [M-1002] 118 10/2007

M-1002 APPENDIX A
8.1.1.1 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 8.1.1.1a
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.
8.1.2 SI Units
0.82
6,500FA ZT
Q a = ------------------------------ ------- Equation 8.1.2a
LC M
0.82
Qa = Gu A (for F=1, see Table A6) Equation 8.1.2b
0.82
Q a = 2G i UA (for F<1, see Table A6) Equation 8.1.2 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 A5)
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:
8U ( 649 – t )
F = -----------------------------
391,800
Gi = the gas factor for insulated containers (see Table A6)

Gu = the gas factor for noninsulated containers (see Table A6)
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.
10/2007 C-III [M-1002] 119

APPENDIX A M-1002
8.1.2.1 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 8.1.2.1a
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.
8.1.3 Alternate Flow Capacity
As an option to the requirements of paragraph 8.1 above, any tank car transporting a non-regu-
lated 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 8.1, that exceeds 19A0.82 (conventional units) or 0.06A0.82 (SI units),
where A is the same value used in the paragraph 8.1 calculation.
8.2 Tank Cars with an Inner Container Tank
The formulas presented below are for liquefied gases in tanks consisting of an inner container sus-
pended in an outer shell. Such tanks are built under Specification AAR-204W or Class DOT-113.
8.2.1 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 gas-
eous lading (whichever requires the greater capacity) at atmospheric pressure:
0.82
Qa = Gi Uc A (conventional or SI units) Equation 8.2.1a
8.2.2 In addition to the requirement of paragraph 8.2.1 above, the pressure relief valve capacity
must be sufficient to limit the pressure within the inner container to the flow rating pressure spec-
ified in the tank specification when the insulation space is filled with air or gaseous lading (which-
ever 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 8.2.2a
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 8.2.2b
( 649 – t 2 )
C-III [M-1002] 120 10/2007

M-1002 APPENDIX A
Notes:
1. In paragraphs 8.2.1 and 8.2.2 above, Uc is the overall thermal conductance of the insulat-
ing material filled with air or gaseous lading, at atmospheric pressure, whichever provides
the greater thermal conductance.
2. In paragraph 8.2.2 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 A6 are given for both rupture disc device
and pressure relief valve settings of Class DOT-113 cars used for these commodities.
9.0 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 9.0a
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 9.0a by using the equation of
state:
pv = ZRT Equation 9.0b
where
v = the gas specific volume in ft3/lb
R = the gas constant
Z = the compressibility factor
Equation 9.0a then becomes

M-
W = CKAp ------ Equation 9.0 c
ZT
10/2007 C-III [M-1002] 121

APPENDIX A M-1002
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 9.0d
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 9.0c can be written as follows:
Ma
W a = C a KAp ------------
- Equation 9.0 e
Za Ta
Solving for KAp,

Wa Za Ta
KAp = -------- ------------
- Equation 9.0 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 k–1
C = 520 k ⎛ ------------ ⎞ Equation 9.0g
⎝k + 1 ⎠
where
Cp
k = ------- Equation 9.0h
Cv
Substituting these values into Equation 9.0f, we obtain the following:

Kap = 0.0119W a Equation 9.0 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 9.0d and Equation 9.0i
in Equation 9.0c as follows:
Q ZT
W a = ------------------------ ------- Equation 9.0 j
0.0119LC M
where
Wa = the air rated equivalent capacity in lb/h at 60 °F inlet temperature
C-III [M-1002] 122 10/2007

M-1002 APPENDIX A
Because we want Wa to be expressed in ft3/min at standard conditions, the following conversion is

made:
Wa vo
( cfm )a = -------------- Equation 9.0k
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 9.0j into Equation 9.0k,

18.34Q ZT
( cfm )a = Q a = ------------------ ------- Equation 9.0 l
LC M
When the specific heat ratio k from which C is calculated is not known, a value of C=315 is consid-
ered a conservative value.
The fundamental equation used in calculating the amount of heat absorbed by a liquid cargo con-
tainer exposed to fire can be expressed as follows:
Q = qFEA w Equation 9.0m
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 9.0m into Equation 9.0l, we obtain the following:

18.34qFEA w
Q a = --------------------------------- ZT
------- Equation 9.0n
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
9.0n gives the following:
633,000FEA w
Q a = ----------------------------------- ZT
------- Equation 9.0 o
LC M
It should be noted that Equation 9.0o 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.
10/2007 C-III [M-1002] 123

APPENDIX A M-1002
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 = -----------
0.18
- Equation 9.0p
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 9.0o is
to equal A, then the product
0.82
Eaw = EA = A Equation 9.0q
Substituting Equation 9.0q into Equation 9.0o,

0.82
633,000FA
Q a = ------------------------------------ ZT
------- Equation 9.0 r
LC M
The definition for F can be typically expressed by the following equation:

U ( t1 – t2 )
F = ------------------------ Equation 9.0 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 9.0 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 37.77 °C (100 °F) multiplied by 2 for a safety factor.
• Assuming that the insulation is rendered 50% ineffective in a fire, the result, again, is mul-
tiplied 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 9.0t becomes the following:
8U ( 1,200 – t 2 )
F = ------------------------------------ Reference Equation 8.1.1d
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 9.0r.
C-III [M-1002] 124 10/2007
M-1002 APPENDIX A
9.1 Derivation of Equation 8.2.1 and Equation 8.2.2—Conventional Units

In the case of paragraph 8.2.1 above, the tank construction consists of an inner container sus-
pended 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 9.1a
34,500
Multiplying and rearranging into Equation 8.1.1a,

0.82
73.4U c ( 1,200 – t 2 )A ZT
Q a = ----------------------------------------------------------- ------- Equation 9.1b
LC M
To simplify use of the formula for commonly encountered gases and pressures, set
73.4 ( 1,200 – t 2 )
G i = --------------------------------------- ZT
------- Equation 9.1 c
LC M
Substituting,
0.82
Qa = Gi Uc A Reference Equation 8.2.1a
The derivation of Equation 8.2.2a 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 9.1d
L
From Compressed Gas Association’s (CGA’s) Basic Consideration for Pressure Relief Device standards,
13.1wC a ZTM a
Q a = ---------------------- -----------------
- Equation 9.1 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 9.1 f
60CL 1.0 ( 520 )M
and
18.3 ( 130 – t 2 )
Q a = ---------------------------------- ZT
-------U c A Equation 9.1g
LC M
From the definition of Gi,

ZT Gi
------- = --------------------------------------------------- Equation 9.1h
M 73.4 ( 1,200 – t 2 ) ⁄ LC
Substituting,
( 130 – t 2 )
Q a = ------------------------------- G i U c A Reference Equation 8.2.2a
4 ( 1,200 – t 2 )
10/2007 C-III [M-1002] 125

APPENDIX A M-1002
Table A3. 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 A3:
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 8.2.1 and Equation 8.2.2.
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.
C-III [M-1002] 126 10/2007

M-1002 APPENDIX A
Table A4. 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 A4:
a. For DOT 113 and AAR 204 cars (cryogenic), use Equation 8.2.1 and Equation 8.2.2.
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 A5. 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.
k-----------
+ 1-
Cp 2 k–1
k = ------- ; C = 520 k ⎛ ------------ ⎞ When C is not shown, 315 is a safe value.
Cv ⎝ k+1 ⎠
10/2007 C-III [M-1002] 127

APPENDIX A M-1002
Table A6. 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
C-III [M-1002] 128 10/2007

M-1002 APPENDIX A

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
10/2007 C-III [M-1002] 129

APPENDIX A M-1002

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
Sulphur dioxide 150 1034 165 1138 37.28 0.1235 4.54 0.0007
Sulphur dioxide 225 1551 247.5 1706 39.58 0.1311 4.69 0.0008
Sulphur 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
C-III [M-1002] 130 10/2007

M-1002 APPENDIX A

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 A6:
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.
10/2007 C-III [M-1002] 131

APPENDIX A M-1002
C-III [M-1002] 132 10/2007

M-1002 APPENDIX B
APPENDIX B
CERTIFICATION AND REGISTRATION OF FACILITIES
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–134
2.0 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–134
3.0 Facility Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–135
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–135
3.2 Material Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–136
3.3 Facility Classes Requiring Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–136
3.4 Facility Classes Requiring Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–137
4.0 Facility Minimum Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–137
4.1 Minimum Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–137
4.2 Minimum Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–138
5.0 Application for Certification or Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–139
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–139
5.2 Data Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–139
5.3 Approval of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–141
6.0 Recertification or Reregistration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–142
6.1 Recertification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–142
6.2 Reregistration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–142
7.0 Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–142
7.1 Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–142
7.2 Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–142
8.0 Facility Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–142
9.0 Facilities in the United States, Canada, and Mexico That Are Certified or Registered in Accord
with Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–143
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–143
9.2 Exhibits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–143
10.0 Nonconformance Reporting—Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–143
10/2007 C-III [M-1002] 133

APPENDIX B M-1002
APPENDIX B
CERTIFICATION AND REGISTRATION OF FACILITIES
1.0 INTRODUCTION
1.1 Scope
1.1.1 Appendix B describes AAR requirements for certification and registration of facilities for
fabrication, assembly, alteration, conversion, repair, associated testing, and qualification of com-
pleted tank car tanks as required by AAR and the Department of Transportation (DOT) or Trans-
port Canada (TC) specifications for tank cars.
1.1.2 This specification has been formulated by the Tank Car Committee of the Association of
American Railroads and includes all applicable portions of Standard S-2034. The Committee con-
sists of representatives appointed by the chief mechanical officers of the major operating railroads.
The Committee is supplemented by representatives from certain shipper organizations.
1.1.3 The application process is fully described and is to be followed by tank car facilities
requesting certification or registration.
1.1.4 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 or registration by the Com-
mittee.
2.0 DEFINITIONS
The definitions and abbreviations in Chapter 1, paragraph 1.2, in Appendix R, and in Appendix W
apply in this appendix as well as the following definitions:
Table B1. General definitions (page 1 of 2)

Assemble Construction of a tank car without welding on the tank car tank.
Certification An acknowledgment from the AAR that a tank car facility has under-
gone inspection and has demonstrated compliance with all applicable
requirements of Appendix B of Section C, Part III, of the AAR Manual of
Standards and Recommended Practices.
Extension A mobile unit under the direction and control of a certified facility. The
extension shall be permitted to perform all work that the parent facility
is certified to perform, provided that the employees are properly
trained, certified, and equipped to perform such work. Extensions are
permitted from AAR Class A, B, and C certified facilities, but are lim-
ited to Class C work only.
Facility, tank car An entity that manufactures, repairs, inspects, tests, qualifies, main-
tains, alters, or converts a tank car, ensuring that the tank car conforms
to published rules, regulations, and specifications.
Maintenance The upkeep or preservation of the condition of a tank car, including
ordinary repairs necessary and proper from time to time for that pur-
pose.
Manufacture To produce a tank car capable of rolling on its own wheels or service
equipment ready to be applied to a tank car.
Qualification A careful and critical examination of a tank car, based on a written pro-
gram, to verify that the tank car conforms to specification, followed by a
representation that the tank car conforms to the specification.
C-III [M-1002] 134 10/2007

M-1002 APPENDIX B
Table B1. General definitions (page 2 of 2)

Registration An acknowledgment from the AAR that a tank car facility has stated
and submitted checklists indicating that the facility meets all the appli-
cable requirements of Appendix B of Section C, Part III, of the AAR
Manual of Standards and Recommended Practices.
Representation Documentation in writing or marking on the tank car tank or jacket
indicating compliance with the specification.
Service equipment Filling, discharge, venting, pressure relief, heating, and measuring
devices.
Tank car A tank car tank mounted on or forming part of a car structure, includ-
ing all components necessary and proper for railroad service.
3.0 FACILITY CLASSIFICATION
3.1 General
3.1.1 Each facility wishing to obtain certification by the AAR Tank Car Committee for
• tank car manufacture
• tank car tank fabrication
• tank car assembly
• tank car repair involving welding or riveting on the tank car tank or removal of deforma-
tions from a tank car tank
• tank car alteration involving welding or riveting on the tank car tank
• tank car conversion involving welding or riveting on the tank car tank
• fabrication of pressure-retaining components
must, as a prerequisite, have or shall have applied for valid certification in accordance with the
AAR M-1003 Specification for Quality Assurance. AAR Tank Car Committee certification will be
revoked from any facility that fails to maintain AAR M-1003 Quality Assurance certification.
3.1.2 Each facility that is to perform welding on tank car tanks must be certified by the AAR for
fabrication, alteration, conversion, or welded repairs. Listings of certified facilities are published
periodically as AAR Circular Letters, including material groups (see paragraph 3.2 below) and
facility class (see paragraph 3.3 below) to identify work that may be undertaken by each facility.
3.1.3 A certified facility that authorizes work using equipment listed in paragraph 4.2 and
paragraph 5.2.1 item 1 of this appendix that is not located on its premises will be responsible for
that work.
3.1.4 Each facility that is to perform welding on tank car tanks must be certified specifically for
one or more of the following material groups, 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.
3.1.5 Except for subcontract facilities described in paragraph 3.3.3, each facility that fabricates
or repairs tank car pressure-retaining components (such as nozzles, sumps, and outlet saddles)
that form an integral part of a tank car tank must have Class D certification or other recognized
certification such as ASME or ANSI. Only those Class D requirements that apply to work done at
the facility must be met.
10/2007 C-III [M-1002] 135

APPENDIX B M-1002
3.2 Material Groups

See Appendix M.
Table B2. 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
3.3 Facility Classes Requiring Certification

Table B3. Facility classes requiring certification
Class Description
Class A Manufacture, repair, alter, convert, or qualify tank cars*
Class B Assemble, repair, alter, convert, or qualify tank cars*
Class C Repair, alter, convert, or qualify tank cars*
Class D Facilities that fabricate, repair, or qualify tank car tanks and/or pressure-retaining tank components that are
moved to and from the facility without trucks (running gear).
Class E* Qualification of tank cars per 49 CFR 180.
* Requires specific certification for this function by the Quality Assurance Committee
3.3.1 Class B and C facilities need not possess all equipment listed in paragraph 4.2 below but
must have access to equipment and testing facilities, as applicable.
3.3.2 Certified/registered facilities must be capable of performing, or arrange to have performed,
all associated tank car activities incident to the class for which they are certified so that the com-
pleted car will be in compliance with the DOT/TC regulations and AAR Interchange Rules. A
signed Exhibit R–1 or Form AAR 4-2 must be submitted when required by the specification.
3.3.3 All work performed by subcontractors for a certified facility must be verified by the certified
facility for compliance with all applicable specifications and regulations. A signed Exhibit R–1 or
Form AAR 4-2 must be submitted, as appropriate, when required by the specification.
3.3.4 An extension of a certified facility must have in its possession the tools, equipment, and doc-
umentation mandated by the Quality Assurance Program for the scope of work being performed.
C-III [M-1002] 136 10/2007

M-1002 APPENDIX B
3.4 Facility Classes Requiring Registration

Table B4. Facility classes requiring registration
Class Description of Covered Activities
Class F Manufacture, recondition, repair, retest, or qualify tank car service equipment.
Class G Remove and replace tank car service equipment or change gaskets (except that the following operations do
not require registration:
• 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 plugs, chains, and flanges external to
valves).
Gaskets and O-rings must be compatible with lading.
Class L Install, qualify, or repair interior linings and coatings in tank cars that transport materials that are corrosive to
the tank as defined in Appendix L, paragraph 8.0.
3.4.1 Class A, B, C, D, and E facilities may perform Class F, G, and L functions without further
registration, provided that those functions are in accord with their approved Quality Assurance
Program. Class L facilities may perform Class G functions without further registration, provided
that those functions are included in the facility’s approved quality assurance program. Class L
facilities must have Class F registration to perform retests of pressure relief valves.
3.4.2 Class F, G, and L facilities need not possess all equipment listed in paragraph 4.2 below, but
must have access to equipment and testing facilities needed to perform the activities within their
scope of registration.
3.4.3 Class F facilities performing service equipment qualification must be capable of performing,
or arrange to have performed, all associated activities incident to the class for which they are reg-
istered.
3.4.4 All work performed by outside subcontractors for a registered facility must be verified by
the registered facility for compliance with all applicable specifications and regulations. A signed
Exhibit R–1 or Form AAR 4-2 must be submitted, as appropriate, when required by the specifica-
tion.
4.0 FACILITY MINIMUM REQUIREMENTS
4.1 Minimum Personnel Qualifications
4.1.1 Welders and Welding Operators
4.1.1.1 All personnel engaged in welding on tank car tanks must be performance-qualified in
accord with Appendix W for each welding procedure under which they do welding. Welders certi-
fied per Appendix W shall be considered to meet the requirements of paragraph 5.1.10.2 of
M-1001, AAR Manual of Standards and Recommended Practices.
4.1.1.2 All other welders at a certified facility, or welders at a registered facility performing work
that requires registration, must be qualified per paragraph 5.1.10.2 of M-1001, AAR Manual of
Standards and Recommended Practices.
10/2007 C-III [M-1002] 137

APPENDIX B M-1002
4.1.2 Inspection Personnel—Welding, Nondestructive Testing, and Coating/Lining

Inspection
4.1.2.1 All certified or registered facilities performing weld inspections must have available at
least one person qualified per the following:
• Welding inspector per Appendix T
• Nondestructive examiners per Appendix T, for methods employed
4.1.2.2 All welding inspectors at certified or registered facilities must be qualified per Appendix
T, except as noted below.
4.1.2.3 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. The certified or registered 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.
4.2 Minimum Equipment Requirements
4.2.1 When a facility subcontracts any of the following services or equipment, the facility must
verify the service using an Exhibit B-1 form:
• Welding inspector per Appendix T
• Hardness testing
• Interior coating / lining applicator and inspector
• NDT equipment
• NDT personnel
• PWHT
• Service equipment maintenance and testing
• Measuring and test equipment and calibration/verification services
• Welding rod ovens (only when using low-hydrogen electrodes)
• Welding machines
4.2.2 A company representative who is responsible for the activity must attest and affirm on the
Exhibit B-1 form that the subcontractor uses the appropriate personnel, process, or equipment to
meet the requirements of the specification. Each facility shall: (1) ensure on a continuing basis
that its subcontractors perform work in accordance with the specification; (2) renew the Exhibit
B-1 form at least annually; and (3) renew the Exhibit B-1 form when a change to personnel, pro-
cess, or equipment invalidates the current Exhibit B-1 form.
4.2.3 For clarity, the following services do not require an Exhibit B-1 form:
• Tank interior cleaning services
• Exterior paint application services
• Head shield repairs (including inserts)
• Jacket repairs
• Purchasing new service equipment
• Purchasing or repairing parts common to all freight cars
C-III [M-1002] 138 10/2007

M-1002 APPENDIX B
5.0 APPLICATION FOR CERTIFICATION OR REGISTRATION

5.1 General
Original and one copy of the application must be submitted to the Executive Director—Tank Car
Safety, AAR, 50 F Street N.W., Washington, D.C. 20001-1564.
5.2 Data Required
5.2.1 Application for Certification (Class A, B, C, or D)
The following data must be submitted as a part of the application:
Table B5. Information required for application for certification (page 1 of 2)
1. Inventory of the equipment (in-house and/or subcontractor), including the following, as may be applicable:
a. Statement that Class A or D facility possesses the jigs, fixtures, and welding and fabricating equipment necessary
to fabricate tanks per AAR Specification M-1002 and all applicable DOT and Transport Canada regulations
b. Postweld heat-treatment equipment for unit and local treatment in accord with Appendix W, paragraph 17.0, and
Appendix R, paragraph 20.3
c. Nondestructive testing equipment
Fluorescent penetrant
Dye penetrant
Magnetic particle
Ultrasonic
Radiographic
i. Type of equipment
ii. Film storage
iii. Film viewer
d. Hardness testing equipment
e. Hydrostatic testing equipment for tank and heater coil testing
f. Pressure relief valve test equipment
2. Description of equipment must show the following (where applicable):
a. Manufacturer’s name
b. Type
c. Model
d. Capacity
e. Ownership if not in-house
3. Current qualification test results for a material listed in each material group for which certification is requested, including
a copy of Welding Procedure Qualification Record (PQR), Appendix W, Fig. W13, with the following:
a. Data illustrating preparation of abutting plate edges.
b. Tabular data outlining welding standards for current, voltage, speed, and wire size as used in welding plates of
various thicknesses for each material group for which certification is requested.
c. Tests performed on an approved plate material for tank fabrication as listed in Appendix M, paragraph 3.0.
4. List of welders, by name and identification symbol, qualified per Appendix W and employed at the facility and its exten-
sions. One or more welders qualified as defined in Appendix W for each material group for which certification is requested
must be employed at the facility. One copy of Welder Performance Qualification Test, Appendix W, Fig. W14, is to be in-
cluded for each material group for which certification is requested.
10/2007 C-III [M-1002] 139

APPENDIX B M-1002
Table B5. Information required for application for certification (page 2 of 2)

5. Organization charts of production and quality control staffs, including extension personnel. Statement describing key per-
sonnel responsible for supervising production, repair, testing tanks, and ensuring quality in compliance with AAR stan-
dards, including the following:
a. Title
b. Outline of duties
c. Delegated authority
d. Level to which certified [for nondestructive testing (NDT), welding inspection, and coating/lining inspection]
e. Experience, education, and training
6. Statement that the facility and all extensions have a quality assurance program that will ensure compliance with all appli-
cable requirements of this specification, related AAR rules and specifications, federal regulations, and individual respon-
sibility for quality.
7. Statement that the facility possesses the latest published issues of the Specifications for Tank Cars, Field Manual of the
AAR Interchange Rules, and Office Manual of the AAR Interchange Rules, and other current applicable AAR publications
covering tank car work it certifies as meeting AAR requirements, including a current file of Safety and Operations publi-
cations (Circular Letters). A listing of current AAR publications is shown on the preface page of this manual. AAR publi-
cations can be obtained from the following location:
Transportation Technology Center, Inc.
P.O. Box 11130
55500 DOT Road
Pueblo, CO 81001
Telephone 877-999-8824 (toll-free)
FAX 719-584-7157
Web site: http://www.aarstore.org
8. Other data as required.
9. Each certified facility will have a unique identifier added to the station stencil for each extension.
C-III [M-1002] 140 10/2007

M-1002 APPENDIX B
5.2.2 Application for Registration (Class F, G, or L)

5.2.2.1 The following items must be submitted as part of the application:
Table B6. Information required for registration
1. Organization charts of process and quality control staffs
2. Statement describing key personnel responsible for supervising repairs, for inspection, and for ensuring quality in com-
pliance with AAR standards, including the following:
a. Title
b. Outline of duties
c. Delegated authority
d. Level to which registered (for NDT, weld, coating, and/or lining inspection)
e. Experience, education, and training
3. Exhibit B–3, including statement verifying compliance with 49 CFR 179.7
4. Registration checklist
5.2.2.2 Inspection of facility or operations by the AAR is optional. Registration may be withheld
or withdrawn if inspection results in findings of inadequate equipment or records or if untrained
personnel are performing work.
5.3 Approval of Application
5.3.1 Certification
5.3.1.1 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.
5.3.1.2 The Executive Director—Tank Car Safety (the Director) must provide for review of the
completed application. If all requirements have been complied with, the Director will appoint a
task force representing the Tank Car Committee to inspect the facility involved. Upon the recom-
mendation of the task force, the Tank Car Committee will consider certification.
5.3.1.3 Approval of a facility will be based on the inspection report, as outlined in Exhibit B–2,
furnished by the evaluator(s) to the Director. This report shall indicate compliance with all
requirements of M-1002, S-2034, and federal regulations applicable to the classification of the
facility.
5.3.1.4 Upon receipt of the report of the inspection task force, the Director will review and for-
ward it to the Tank Car Committee for action.
5.3.1.5 In the event the Tank Car Committee finds that the applicant’s facility is not suitable for
certification, the applicant may request a reinspection of the facility. The applicant must bear all
expenses of this reinspection. If upon review of the results of such inspection, the Tank Car Com-
mittee still does not consider the facility suitable for certification, the matter may be appealed to
the Assistant Vice President, Environment and Hazardous Materials. Such appeal may be accom-
panied by any comments, explanations, or evidence in support of such appeal that the applicant
desires to submit.
5.3.1.6 The initial certification of a facility is conditional. After receipt of conditional approval,
the facility is required to advise the Director regarding the first tank work in process. A Form
AAR 4-2, if required, must be submitted and approved prior to beginning the work. At the discre-
tion of the Tank Car Committee, the first car is subject to inspection. Based upon that inspection,
final action will be taken by the Committee to remove conditional status. The applicant will bear
all costs for reinspection. Conditional certification will lapse, in the absence of shop activity on a
tank car, at the end of a two-year period, after which time certification proceedings must be reiniti-
ated. Facilities holding conditional approval will not be listed in published listings of certified facil-
ities.
10/2007 C-III [M-1002] 141
APPENDIX B M-1002
5.3.2 Registration
5.3.2.1 Approval under this specification applies to only one facility. If a company desires that
more than one facility be approved, each facility must be approved independently.
5.3.2.2 Approval is effective upon receipt from the AAR of a signed copy of the properly completed
form.
6.0 RECERTIFICATION OR REREGISTRATION
6.1 Recertification
6.1.1 Facilities must be recertified at intervals of six years from the original certification date in
accord with procedures prescribed for an original certification. It is the responsibility of the facility
to initiate these certification proceedings six months prior to the expiration date.
6.1.2 Effective at the next recertification, a facility that has not made an approved welded repair
in the two years prior to its certification expiration date will be considered for conditional certifica-
tion only and processed in accord with paragraph 5.3.1.2 above.
6.1.3 A change in ownership of a certified facility requires reconsideration of certification. It is
the responsibility of the new owner to initiate recertification proceedings within 90 days.
6.1.4 In addition to the data required per paragraphs 4.1, 4.2, and 5.2 of this appendix, applica-
tions for recertification must include copies of a typical Exhibit R–1 and an approved Form
AAR 4-2, with a description of how these documents are originated, processed, and stored. (Class
E is excluded from this requirement.)
6.2 Reregistration
6.2.1 Facilities must be registered at intervals of six years from the original registration date in
accord with procedures prescribed for an original registration. It is the responsibility of the facility
to initiate these registration proceedings 6 months prior to the expiration date.
6.2.2 A change in ownership of a registered facility requires reconsideration of registration. It is
the responsibility of the new owner to initiate reregistration proceedings within 90 days.
7.0 CHARGES
7.1 Certification
Application for initial certification or for recertification must be accompanied by an initial pay-
ment of US$500 to apply toward the inspection fee. Upon completion of the inspection, an invoice
will be issued for the current facility inspection fee and any expenses incurred.
7.2 Registration
An initial charge of U.S. $180 will be made for registration or reregistration for each facility to
apply toward technical review and administrative expenses.
8.0 FACILITY INSPECTIONS
8.1 The Committee reserves the right to inspect certified or registered facilities at any time to
ensure maintenance of certification standards. This right also includes unannounced inspections
by AAR inspectors, who will furnish reports of deficiencies in writing to the Tank Car Committee.
8.2 Car owners, certified facilities, and registered facilities have the right and responsibility to
make report of improper repairs to the Director for review by the Tank Car Committee. The Direc-
tor may authorize an unannounced inspection of a facility and may request copies of repair records
on subject cars from the involved parties.
8.3 A facility may have certification or registration withdrawn by formal action of the Tank Car
Committee for documented evidence of failure to meet the requirements of M-1002. In such cases,
C-III [M-1002] 142 10/2007
M-1002 APPENDIX B
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 accomplished via on-site verification by representatives of the Tank Car Committee.
Reapplication must be in accord with specified procedures for an original application.
9.0 FACILITIES IN THE UNITED STATES, CANADA, AND MEXICO THAT ARE
CERTIFIED OR REGISTERED IN ACCORD WITH APPENDIX B
9.1 General
Facilities that currently are certified or registered to perform work in accord with AAR Specifica-
tions for Tank Cars, Appendix B, are published periodically as AAR Circular Letters. Prior to
authorizing work on a tank car at a facility not published in an AAR Circular Letter, contact the
Executive Director—Tank Car Safety, Association of American Railroads, 50 F Street N.W., Wash-
ington, D.C. 20001-1564, to determine if appropriate certification or registration of the facility will
be in effect at the time of the performance of the work (telephone 202-639-2147; fax 202-639-2930;
e-mail pkinnecom@aar.org).
9.2 Exhibits
• Exhibit B–1 Subcontractor Evaluation Sheet . . . . . . . . . . . . . . . . . . . . . page C-III–144

• Exhibit B–2 AAR Tank Car Committee Shop Evaluation . . . . . . . . . . . . page C-III–145
• Exhibit B–3 Registration for Class F, G, and L Facilities. . . . . . . . . . . . . page C-III–150
10.0 NONCONFORMANCE REPORTING—RESPONSIBILITIES

10.1 Car owners, railroads, shippers, and certified or registered facilities shall report instances of
nonconformance from this specification produced by certified facilities using the nonconformance
codes published by the AAR Quality Assurance Committee. The report shall be made in accor-
dance with AAR Manual of Standards and Recommended Practices, Section J, Specification M-
1003, Chapter 7, and sent to the AAR Quality Assurance Committee, the certified facility, and the
car owner using Form QA-7.1 and Fig. 7.4, “Process Map for Reporting Tank Car Nonconfor-
mance,” both in said Chapter 7. The initiator shall identify the contractor producing the nonconfor-
mance.
10.2 Nonconformance from this specification produced by registered facilities shall be reported to
the Executive Director—Tank Car Safety, the registered facility, and the car owner, using Form
Form QA-7.1 and the nonconformance codes published by the AAR Quality Assurance Committee.
(For the reader’s convenience, a copy of Form QA-7.1 and Form QA-7.2 are included at the back of
this manual.) The initiator of the nonconformance report shall identify the contractor producing
the nonconformance.
10/2007 C-III [M-1002] 143

APPENDIX B M-1002
EXHIBIT B–1
SUBCONTRACTOR EVALUATION SHEET
Each facility shall complete and retain an original copy of this form for each listed Appendix B subcontractor. A
company representative responsible for the activity shall attest and affirm, by signing this form, 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.
SUBCONTRACTOR COMPANY NAME
SUBCONTRACTOR COMPANY ADDRESS
SERVICE, PRODUCT, OR EQUIPMENT

PROVIDED BY THE SUBCONTRACTOR
SUBCONTRACTOR COMPANY CONTACT
COMPANY REPRESENTATIVE (ATTESTING)
DATE VERIFIED
DATE OF EXPIRATION
SUBCONTRACTED ACTIVITY
(PLEASE CHECK ALL THAT APPLY) PERSONNEL PROCESSES EQUIPMENT
FOR EACH CHECK ABOVE, PLEASE EXPLAIN HOW THE COMPANY REPRESENTATIVE RESPONSIBLE FOR THE ACTIVITY VERIFIES THAT THE
SUBCONTRACTOR UNDERSTANDS AND CONFORMS TO THE REQUIREMENTS OF THE ASSOCIATION OF AMERICAN RAILROADS’ SPECIFICATIONS FOR
TANK CARS, M-1002.
PERSONNEL:
PROCESSES:
EQUIPMENT:
C-III [M-1002] 144 10/2007

M-1002 APPENDIX B
Exhibit B-2 AAR Tank Car Committee Shop Evaluation
EXHIBIT B–2
AAR TANK CAR COMMITTEE SHOP EVALUATION
To: Executive Director—Tank Car Safety
Facility________________________________ Station Stencil ____________________________________
Facility Contact ___________________________________________________________________________
Location: Address _________________________________________________________________
City __________________ State ____________________Phone___________________
Requested Class: A B C D
Material Groups: 1 2 3 4 7 Including/Excluding TC128
Size of Workforce_______________________ Shop Dedicated to:
Evaluation
Element Remarks
Yes No
Conformance to building specifications
Welding, fabrication, and construction
practices
Quality control
Facilities
Operations
Test devices
Maintenance
Engineering and drafting
Evaluator’s comments:
RECOMMENDATION: I/We inspected this facility on _____________ (date) and found/did not find the
equipment, personnel, and records to be as listed in the Request for Certification dated ____________.
I/We recommend/do not recommend certification of the facility as Class _____________,
Material Groups _____________, including/not including TC-128.
I/We recommend conditional/unconditional certification.
Inspector: _________________________________ ____________________________________
Title: _____________________________________ ____________________________________
Organization:______________________________ ____________________________________
Date: _____________________________________ ____________________________________
Signature:_________________________________ ____________________________________
10/2007 C-III [M-1002] 145

APPENDIX B M-1002
EXHIBIT B–2
(CONTINUED)
Facility Evaluation
Element Remarks
Class Yes No
1.0 CONFORMANCE TO BUILDING
SPECIFICATIONS
A. Where AAR approval is required by
specifications, sublet fabrication or A, B
manufacture must be awarded to
manufacturers holding appropriate
approval.
B. Materials must be identified when
transferred from storage to shop pri- A, B, C, D
or to processing.
2.0 WELDING, FABRICATION AND
CONSTRUCTION PRACTICES
A, B, C, D
A. The procedures outlined in Appendix
W of M-1002 must be followed.
B. Welding procedures and welding pro-
cedure qualifications must conform A, B, C, D
to Appendix W of M-1002.
C. Tank car materials must conform to
A, B, C, D
Appendix M of M-1002.
D. Welder qualifications must conform
A, B, C, D
3.0 QUALITY CONTROL
A. Quality assurance program must be A, B, C, D
maintained in accordance with AAR
Specification M-1003.
B. Inspectors must have the following
equipment available and in use:
A, B, C, D
Welding gauges
Tag system
C. There must be testing equipment or
a testing service available to verify
A, B, C, D
conformance of material to specifica-
tions.
D. Names, titles, and duties of shop and
quality control personnel must con-
A, B, C, D
form to the application. List those in-
terviewed.
E. Welding inspector and non-
destructive examiners must be
A, B, C, D
available in accordance with Appen-
dix B, paragraph 4.1.
C-III [M-1002] 146 10/2007

M-1002 APPENDIX B
EXHIBIT B–2
(CONTINUED)
Facility Evaluation
Element Remarks
Class Yes No
F. Check Exhibit B–1 subcontractor
A, B, C, D
documents for completeness.
4.0 FACILITIES
A. The facility must have a transfer ta- A, B
ble or other mechanism to simulate
AAR minimum curve requirements.
B. The facility must have possession of
or access to scale for weighing of cars.
A, B
(Capacity, length of scale, and certifi-
cation to be provided by facility.)
C. The facility must have designated
level track for adjustment of side A, B, C
bearings and coupler height.
D. The applicant must have necessary
and operable equipment on premises A, B, C, D
to perform the intended work.
E. There must be proper storage for
welding electrodes, fittings, valves, A, B, C, D
brake valves, and brake cylinders.
F. There must be sufficient flux and/or
rod ovens in use to support the
A, B, C, D
operations per Appendix W and AWS
D15.1.
G. Radiography equipment and
postweld heat treatment facilities A, B, C, D
must be available.
H. Radiographs must meet the require-
ments of Appendix W,
A, B, C, D
paragraph 11.0, and must be stored
in an acceptable manner.
I. Radiographs must be maintained for
A, B, C, D
the required time.
5.0 OPERATIONS
A. Raw material must be blocked and A, B, C, D
handled to prevent permanent
distortion.
B. The facility must have yard space,
handling equipment, and other
A, B, C, D
equipment to store and handle mate-
rials.
10/2007 C-III [M-1002] 147

APPENDIX B M-1002
EXHIBIT B–2
(CONTINUED)
Facility Evaluation
Element Remarks
Class Yes No
C. Work in progress must comply with
M-1002:
Welding
Stenciling
A, B, C, D
Lining
Repairs
Nondestructive Testing
Other
6.0 TEST DEVICES
A. The facility must have AAR-ap- A, B
proved brake shoe force measuring
devices available.
B. The facility must have hand brake
A, B
force measuring device available.
C. The facility must have single car test
A, B, C
device.
D. The single car test device must be
verified in accordance with the latest A, B, C
AAR requirements.
E. The facility must have a brake pipe
restriction test device and calibrat- A, B
ing test coupling.
F. The facility must have available a
brake pipe restriction test device and C
calibrating test coupling.
G. The brake pipe restriction test device
must be tested in accord with the lat- A, B, C
est AAR requirements.
H. The facility must have calibrated hy-
drostatic test equipment (where re- A, B, C, D
quired.)
I. The facility must have calibrated
pressure relief valve testing equip- A, B, C, D
ment available (where required).
7.0 MAINTENANCE
A. Equipment, tools, welding machines, A, B, C, D
etc., as submitted must be main-
tained in proper working order.
C-III [M-1002] 148 10/2007

M-1002 APPENDIX B
EXHIBIT B–2
(CONTINUED)
Facility Evaluation
Element Remarks
Class Yes No
8.0 ENGINEERING AND DRAFTING
A. The company must have in-house en-
gineering and drafting capability A, B
with a manager who holds a degree
in engineering.
B. Personnel responsible for supervis-
ing engineering, production, repair,
testing and quality assurance must A, B, C, D
have knowledge of the applicable
codes and specifications.
C. The facility must have a current li-
brary of specifications (latest revi-
sions) of all manuals applicable to
work being performed, such as:
Field Manual of the AAR Interchange
Rules
Office Manual of the AAR Interchange A, B, C, D
Rules
AAR Manual of Standards, M-1002
FRA or TC Safety Appliance Standard
AAR Circulars
BOE Tariff 6000 or 49CFR (US only)
CGSB Standard 43.147 (Canada only)
TDG Regulations (Canada only)
D. The company must have in-house de-
sign engineers or it must consistent-
A, B
ly use consultants qualified by
registration or experience.
E. (The facility must have personnel ca-
pable of supervising, evaluating and
A, B, C, D
coordinating outside shop detail
drawings and/or specialty drawings.
9.0 OTHER (GIVE DETAILED
DESCRIPTION)
10/2007 C-III [M-1002] 149

APPENDIX B M-1002
EXHIBIT B–3 Exhibit B-3 Registration for Class F, G, and L Facilities
REGISTRATION FOR CLASS F, G, AND L FACILITIES
Executive Director—Tank Car Safety

50 F Street N.W.
Request to register the facility or operation designated below that performs the work as outlined
in this registration, in accord with federal regulations at 49 CFR 180 and Appendix B of Specifica-
tion M-1002, Specification for Tank Cars.
This is to attest that the facility or operation described below meets the compliance requirements
of 49 CFR 179.7 and M-1002, Appendix B, paragraph 3.4, per the attached checklist.
Company
Facility
Address
Phone number Fax number
Activities performed at this facility:
Class F
Class G
Class L
Signed Title
Print name Date
Signature for Executive Director—Tank Car Safety
Date registered Station stencil (assigned)
C-III [M-1002] 150 10/2007

M-1002 APPENDIX B
EXHIBIT B–3
(CONTINUED)
REGISTRATION CHECKLIST
Instructions: List in column (2) the company document or procedure number where the element in
column (1) is defined.
(1) (2)
Company Document
Element or Procedure Number
1.0 SCOPE
Scope of work for which you are requesting registration.
2.0 ORGANIZATION
A. Responsibilities of QA personnel defined, highlighting the following
functions: performance and management of QA work and verifica-
tion of conformance to QA requirements (identifying, recording, and
correcting nonconformances).
B. Positions to which each of the tasks shown in 2.0A are assigned and
each position’s relationship to the organization (organization chart).
3.0 INSPECTION AND TEST PLAN
A. Inspection and test plan.
B. Where subcontractor’s services will be utilized
C. Methods employed by contractor to verify subcontractor quality per-
formance.
D. Verification methods to be employed for special process procedures.
4.0 DOCUMENT CONTROL
Current issues of applicable documents are available and accessible at all
applicable functional areas. A list of applicable publications required to
keep current.
5.0 MEASURING AND TEST EQUIPMENT
A system is provided to ensure that all measuring and test equipment and
devices used to verify quality and monitor special processes are controlled,
maintained, and properly documented.
6.0 INCOMING INSPECTION
Provisions are made to inspect, test, and identify incoming items as
required by the inspection and test plan.
7.0 FINAL INSPECTION
Provisions are made to inspect, test, identify, and document the final items
as required by the inspection and test plan.
8.0 SPECIAL PROCESSES
Provisions are made to ensure that the qualifications of personnel, process-
es, and equipment comply with requirements of applicable specifications,
codes, and standards and are properly documented.
9.0 QUALITY RECORDS
Provisions are made to maintain quality records as evidence that the refer-
ence drawing number and revision number or part number of the item are
identified.
10/2007 C-III [M-1002] 151

APPENDIX B M-1002
EXHIBIT B–3
(CONTINUED)
(1) (2)
Company Document
10.0 NONCONFORMANCE
Provisions are made for the retention, evaluation, and disposition of all
nonconforming items, including those of subcontractors.
11.0 INTERNAL QUALITY AUDITS
Internal quality audits are planned, scheduled, and documented at least
once per year to verify compliance with specifications.
12.0 TRAINING
A. Approved procedures for identifying training needs and providing
training for all personnel involved in quality have been established.
B. Personnel performing specific tasks are qualified on the basis of ap-
propriate education, training, and/or experience.
C. Records of training are maintained
D. Measures to ensure that personnel are aware and knowledgeable of
their specific responsibilities for quality have been defined.
E. The necessary instruction and means whereby those personnel can
develop, achieve, and maintain proficiency are provided.
13.0 DESIGN CONTROL
A. Design input requirements, including contract review activities, are
documented, clarified, and reviewed for adequacy.
B. The design outputs meet design input requirements.
C-III [M-1002] 152 10/2007

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

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–154
3.0 Stenciling of Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–154
3.1 New Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–154
3.2 Repainted Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–154
3.3 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–154
4.0 Tank Identification Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–159
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–159
4.2 Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–160
5.0 Placard Holder or Permanent Placards (Decal or Stencil). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–161
5.1 When Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–161
5.2 Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–161
6.0 AAR Commodity Marking Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–161
6.1 Tank Cars without Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–161
7.0 Load Limit Stencil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–161
8.0 Bolted and Hinged Manway Style Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–162
9.0 Retroreflective Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–162
9.1 Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–162
9.2 Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–162
9.3 Retroreflective Surface Area per Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–163
9.4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–163
10/2007 C-III [M-1002] 153

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 Recom-
mended Practices, Section L, Standard S-910.
2.0 DEFINITIONS
this appendix:
Table C1. General definitions
Lining For stenciling purposes, lining or coating is identified as “lining”
on the qualification stencil
Marked Applied with either stencil or decal
Rules AAR interchange rules
Service equipment Equipment used on a tank car for filling and discharge, venting,
pressure relief, vacuum relief, heating, and measuring
Stamped Steel-stamped
Stenciled Applied with paint or decal
3.0 STENCILING OF TANK CARS
3.1 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. C2 and Fig. C3. When stenciling is prescribed on tank and tank is insulated, the
stencils must be applied on the jacket.
3.2 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:
3.3 Notes
See Fig. C2 and Fig. C3.
C-III [M-1002] 154 10/2007

M-1002 APPENDIX C
3.3.1 Tanks
3.3.1.1 Initials and number of DOT, TC, or AAR specifications applicable to the tank car’s oper-
ating specification must be stenciled on both sides of the tank in letters and numerals at least 1 1/2
in. (38.1 mm) high.
3.3.1.2 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, begin-
ning 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.
3.3.1.3 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.
3.3.1.4 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.
3.3.1.5 When exterior thermal coatings are applied, see Field Manual of the AAR Interchange
Rules, Rule 80.E.1 for marking requirements.
3.3.1.6 A qualification stencil is to be applied at the time that the tank is qualified.
3.3.1.7 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.
3.3.1.8 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.
3.3.1.9 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.
3.3.1.10 Stub sill, nonpressure, nonexterior-coiled tank cars built prior to July 1, 1974, that qual-
ify 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 Engi-
neering Committee.
3.3.1.11 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 Inter-
change Rules, Rule 70.
3.3.1.12 Stencil CO2 tank cars with the stencils specified in Chapter 2, paragraph 2.1.1.
3.3.1.13 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.
3.3.1.14 Tank cars with interior lining or coating are to be marked per paragraph 3.3.3.3 below.
10/2007 C-III [M-1002] 155
APPENDIX C M-1002
3.3.2 Running Gear

3.3.2.1 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 sten-
ciled on both truck bolsters.
3.3.2.2 The consolidated stencil for lubrication and air brakes is to be applied in accord with Field
Manual of the AAR Interchange Rules, Rule 80.
3.3.2.3 When the owner desires cars to be marked to provide information with respect to cou-
plers, 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 3.3.4.7 below.
3.3.2.4 The brake lever diagram metal badge plate must be located as shown in Figs. C2 and C3.
See Field Manual of the AAR Interchange Rules, Rule 88.
3.3.2.5 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 3.3.3.4 below.
3.3.2.6 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.
3.3.3 Inspection and Test
3.3.3.1 Tank Qualification
3.3.3.1.1 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. C5 or Fig. C9) in let-
ters and numerals at least 1 in. (25.4 mn) high. A station stencil is required.
3.3.3.1.2 The year in which a tank thickness test is performed must be applied and/or maintained
in the location specified on the qualification stencil (Fig. C5 or Fig. C9) in letters and numerals at
least 1 in. (25.4 mm) high. A station stencil is required.
3.3.3.2 Service Equipment Qualification
3.3.3.2.1 The year in which the service equipment (except items covered in paragraphs 3.3.3.2.2,
3.3.3.2.3, and 3.3.3.2.4 below) is qualified and the qualification due date must be applied and/or
maintained in the location specified on the qualification stencil (Fig. C5 or Fig. C9) in letters and
numerals at least 1 in. (25.4 mm) high. A station stencil is required.
3.3.3.2.2 The type of pressure relief device must be applied and/or maintained in the location
specified on the qualification stencil (Fig. C5 or Fig. C9) 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.
3.3.3.2.2.1 The start-to-discharge pressure of a reclosing pressure relief device or the burst pres-
sure of a rupture disk or breaking pin must be applied and/or maintained in the location specified
on the qualification stencil (Fig. C5 or Fig. C9) 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).
3.3.3.2.2.2 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. C5 or Fig. C9) in letters and numbers at least 1 in. (25.4 mm high). Station stencil of facility
applying the device is required.
C-III [M-1002] 156 10/2007

M-1002 APPENDIX C
3.3.3.2.3 Tank cars with interior heater systems must have the stencil “INT HTRS” applied
and/or maintained in the location specified on the qualification stencil (Fig. C5 or Fig. C9) in let-
ters at least 1 in. (25.4 mm) high.
3.3.3.2.3.1 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. C5 or Fig. C9) in letters and numerals at least 1 in. (25.4 mm) high. A station stencil is
required.
3.3.3.2.3.2 Exterior heater systems do not require requalification.
3.3.3.2.4 Tank cars with a sparger system must have the stencil “SPGR” applied and/or main-
tained in the location specified on the qualification stencil (Fig. C5 or Fig. C9) in letters at least
1 in. (25.4 mm) high.
3.3.3.2.5 When service equipment qualification occurs at more than one facility, the station sten-
cil 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.
3.3.3.3 Coating/Lining Qualification
3.3.3.3.1 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 qualifica-
tion and due dates on the qualification stencil. A station stencil is required.
3.3.3.3.2 The year in which the coating or lining is inspected and the inspection due date must be
applied and/or maintained in the location specified on the qualification stencil (Fig. C5 or Fig. C9)
in letters and numerals at least 1 in. (25.4 mm) high. A station stencil is required.
3.3.3.4 88.B.2 Inspection
The year in which a Rule 88.B.2 inspection is performed and the inspection due date must be
applied and/or maintained in the location specified on the qualification stencil (Fig. C5 or Fig. C9)
in numerals at least 1 in. (25.4 mm) high. A station stencil is required.
3.3.3.5 Stub Sill Inspection
The year in which a stub sill inspection is performed and the inspection due date must be applied
and/or maintained in the location specified on the qualification stencil (Fig. C5 or Fig. C9) in
numerals at least 1 in. (25.4 mm) high. A station stencil is required.
3.3.4 General
3.3.4.1 The location, sizes, and spacing of letters and numerals must be as shown in Figs. C2 and
C3.
3.3.4.2 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 longitudi-
nal 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.
3.3.4.3 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.
10/2007 C-III [M-1002] 157

APPENDIX C M-1002
3.3.4.4 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. C2 and Fig. C3. 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.
3.3.4.5 The sum of the load limit and the car light weight must not exceed the rail load limit,
based on axle capacity.
3.3.4.6 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.
3.3.4.7 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 3.3.2.3 above; for example, “No. 18 BR BM”
for Number 18 brake beam.
Table C2. Optional abbreviations for tank car stenciling
Abbreviation Definition Abbreviation Definition

BM Beam LMT Limit
BOT Bottom LD Load
BR Brake LUB Lubricated
BLT Built MAG Magnetic
CAPY Capacity MO Month
COMB PRD Combination pressure relief device NO Number
COMP Composition OPR Operated
CONT Controls PP Product purity
CONV Converted PRD Pressure relief device
CPL Coupler PSI Pounds per square inch
CTC Canadian Transport Commission PVC Polyvinyl Chloride
CUFT Cubic Feet RSD Raised
DOT Department of Transportation RPKD Repacked
DFT Draft REQ Required
E Exemption SPGR Sparger
ELEC Electric SPRG Spring
EXT Exterior SP Special Permit
GAL Gallons SR Safety Permit—Rail
GR Gear ST Service Trial
HF High friction STL Steel
HTR Heater STNLS Stainless
IDT In Date Test TC Transport Canada
INT Interior THERMO Thermometer
KG Kilograms W Wear, Wrought
L Liters WT Weight
LB Pounds WHLS Wheels
LT Light
C-III [M-1002] 158 10/2007

M-1002 APPENDIX C
3.3.4.8 When a car is operating under DOT special permit, Canadian safety permit, or AAR ser-
vice trial, the permit or service trial must be identified by a stencil or decal placed above the com-
modity name or tank specification number. If the DOT special permit or Canadian safety permit
grants relief from the marking requirements of 49 CFR 172.302(c), then this AAR marking
requirement is waived. The stencil must have at least 4-in.-high (101.6-mm) letters for DOT-SP or
SR-XXXX. The stencil must have at least 1 1/2-in. (38.1 mm) letters for AAR ST-XXXX.
3.3.4.9 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, fol-
lowed by a term or terms identifying the restriction in letters at least 1 in. (25.4 mm) high. See
also 49 CFR 215.303.
3.3.4.10 If desired by car owner or lessee, a stencil indicating “LEASED TO—COMPANY” 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.
3.3.4.11 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 owner’s 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 owner’s or shipper’s option.
3.3.4.12 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,
S-914.
3.3.4.13 Whenever a year is required to be marked on a tank, it must be marked using four char-
acters (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).
4.0 TANK IDENTIFICATION PLATES
4.1 General
4.1.1 All cars ordered after December 31, 2003, must be equipped with two identical stainless
steel identification plates. Plates must be at least 3/32 in. thick and permanently affixed by weld-
ing or mechanical fasteners in a visible location to the inboard surfaces of the AR and BL body bol-
ster webs or any flashing that covers the body bolster webs. If bolts are used for mounting, the
threads must be deformed to prevent loss of the plates.
10/2007 C-III [M-1002] 159

APPENDIX C M-1002
4.1.2 Plates are to be unpainted and of a size suitable to contain the following items of text. Let-
ters must be a minimum of 3/16 in. high and be clearly stamped, etched, or embossed on the plates.
Carbuilder's Name Full name of the carbuilder as shown on the Certificate of

Construction
Builder's Serial Number Builder's 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 ASTM or AAR specification of the material used to construct
Material 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.
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 data-
base
Date Built Month and year of construction. If the underframe has a dif-
ferent built date than the tank built date, both dates must be
shown.
4.1.3 Any illegible or missing identification plates must be replaced. Information on a replace-
ment plate may be copied from a still-attached identification plate or be supplied by the car owner.
4.1.4 Changes made to a car that would cause the information on the identification plates to be
incorrect will require that new, correct identification plates be applied.
4.1.5 See Fig. C1 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. C1 Marking on an identification plate

4.2 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.
C-III [M-1002] 160 10/2007

M-1002 APPENDIX C
5.0 PLACARD HOLDER OR PERMANENT PLACARDS (DECAL OR STENCIL)

5.1 When Required
5.1.1 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 perma-
nent 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 car’s wheels.
5.1.2 All cars required to be placarded for subsidiary hazards must have dual metal placard hold-
ers 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 car’s wheels.
5.2 Design
See Chapter 5, paragraph 5.1.6, and Appendix E.
6.0 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 applica-
ble regulation.
6.1 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.
7.0 LOAD LIMIT STENCIL
7.1 Effective January 1, 1985, the load limit (instead of nominal capacity) is to be stenciled on all
tank cars built new.
7.2 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.
7.3 Any tank car not stenciled with a load limit must have a load limit stencil applied and the
nominal capacity stencil removed.
7.4 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.
7.5 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 kilograms oth-
erwise 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.
10/2007 C-III [M-1002] 161

APPENDIX C M-1002
8.0 BOLTED AND HINGED MANWAY STYLE MARKING

8.1 For manway styles identified in Tables D7 through D13, at the next tank test, tank or pres-
sure relief device qualification, or owner’s shopping, a manway style decal/stencil per Fig. C4 shall
be applied to an operating platform corner post, on top of the manway cover, or on any other unob-
structed location near the manway on all cars equipped with bolted and hinged manways.
8.2 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 manufacturer’s identification and the numbers indicate the style number
assigned by the manufacturer.
8.3 New cars ordered after July 1, 1996, must be equipped with manway style decals/stencils per
Fig. C4. Manways designed to accommodate the AAR standard gasket, as defined in Appendix E,
paragraph 4.3.5.3, are to be designated “MANWAY STYLE: AAR-1.”
8.4 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.
9.0 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 9.1. For new applications of reflectors to cars with existing
stenciling and for cars whose construction does not permit compliance with paragraphs 9.4.1
through 9.4.4, the minimum area of retroreflective sheeting specified in paragraph 9.3 shall be
applied. The reflectors shall be applied in a manner that complies as closely as possible with these
requirements.
9.1 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 require-
ments of ASTM D 4956-04 for Type V sheeting if metalized or Type VII sheeting if non-metalized.
The characters “FRA-224” constitute the manufacturer’s 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 certifica-
tion shall be spaced no more than 4 in. apart. Retroreflective sheeting shall be yellow or fluores-
cent yellow.
9.2 Size
Individual reflectors are to be 4 in. × 18 in. or 4 in. × 36 in., as practicable. Reflectors may be sepa-
rated into 4-in. × 9-in. strips if necessary and applied on either side of discontinuous surfaces,
appurtenances, or existing or other required car markings.
C-III [M-1002] 162 10/2007

M-1002 APPENDIX C
9.3 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 Retrore- Equivalent Number of

Car Length over End Sills
flective Sheeting 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.
9.4 Location
9.4.1 Reflectors are to be oriented vertically. Reflectors are not to be applied over existing or
required car stencils and markings.
9.4.2 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.
9.4.3 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.
9.4.4 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.
9.4.5 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.
9.4.6 Reflectors, decals, and stenciling are not to be overlapped.
10/2007 C-III [M-1002] 163

A ABCX 00000 G F
B I Y Z
C H J
APPENDIX C
10/2007
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 ½" MAX

4"10 ½" 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 9.0 in this specification.
CAPY 00 000 L
C-III [M-1002] 164

Placement window for typical application of retroreflective sheeting
V
______________
______________
CL HEAD W Notes:
1. See paragraph 9.4.4 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. C2 DOT and AAR stencil requirements for qualified tank cars
M-1002
10/2007
M-1002 APPENDIX C
Call Out Paragraph Reference Call Out Paragraph Reference

A 3.3.4.2 ABCX 00000 O 3.3.1.7—1 1/2 in. minimum
B 3.3.4.3, 3.3.4.5, and 3.3.4.9 Fig. C5 or Fig. C9 Qualification stencil—blank

P (see Fig. C8 for sample of completed
C 3.3.1.11 stencil)
D 3.3.1.10—1 1/2 in. Q 3.3.1.4, 3.3.4.4—1 in. minimum
E 5.1 R 3.3.2.2—consolidated stencil
F Fig. C4 S 3.3.2.6
G 3.3.4.6 T 3.3.4.2—4 in. minimum
H 3.3.1.2—(compartment cars) 1 1/2 in. minimum U 3.3.1.2—1 1/2 in. minimum
I 3.3.3.3.1—Lining application DOT Part 179—3/8-in. letters stamped in both
V heads.
J Remarks c. and e.
3.3.4.4—See remark f.—1 1/2 in. minimum W 3.3.2.3
K
3.3.2.4—Brake lever badge plate (BL only) X 3.3.2.1—1 1/2 in. minimum
L
3.3.2.1—(center sill cars only—1 1/2 in. Y 3.3.1.3, 6.0—commodity name
M minimum) 3.3.4.8—exemptions, safety permits, service
Z trials
N 3.3.1.1—1 1/2 in. minimum
Remarks (paragraph references are to this appendix):

a. For thermal coatings, see paragraph 3.3.1.5.
b. For painting, see paragraph 3.3.1.8.
c. When exterior heater coils are applied, see paragraph 3.3.1.9.
d. For CO2 stencils, see paragraph 3.3.1.12.
e. For leasing stencil, see paragraph 3.3.4.10.
f. For separate built dates of tank and underframe, stencil as shown. Otherwise, built date is part of consolidated
stencil. See paragraph 3.3.4.4 and paragraph 3.3.2.2.
g. Stencils are applied to both sides of car unless otherwise indicated.
h. For “inhalation hazard” stencil, see paragraph 3.3.1.13.
i. Pressure units on existing cars are not required to be changed from “lb” to “psi” until they are repainted.
Fig. C2 DOT and AAR stencil requirements for qualified tank cars (concluded)
10/2007 C-III [M-1002] 165

A ABCX 00000 G F OMIT ON CARS NOT EQUIPPED
WITH INTERNAL HEATER PIPES
B AA AB
C H J
M
APPENDIX C
N
10/2007
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 ½" MAX

4"10 ½" 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 9.0 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] 166

*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 9.4.4 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. C3 DOT and AAR stencil requirements for other tank cars*
M-1002
10/2007
M-1002 APPENDIX C
Call Out Paragraph Reference Call Out Paragraph Reference

A 3.3.4.2 ABCX 00000 O 3.3.3.2.2.1
B 3.3.4.3, 3.3.4.5, and 3.3.4.9 P 3.3.3.1, 3.3.3.2—1 in. minimum
C 3.3.1.11 Q 3.3.1.4, 3.3.4.4—1 in. minimum
D 3.3.1.10—1 1/2 in. R 3.3.3.3.1—2 in. minimum
E 5.1 S 3.3.2.2 —consolidated stencil
F Fig. C4 T 3.3.2.6
G 3.3.4.6 U 3.3.1.6—1 in. minimum
H 3.3.1.2—(compartment car) 1 1/2 in. minimum V 3.3.4.2—4 in. minimum
I 3.3.4.4—See remark f.—1 1/2 in. minimum W 3.3.1.2—1 1/2 in. minimum
J Remarks c. and e. X DOT Part 179—3/8-in. letters stamped in both

heads.
K 3.3.2.4—Brake lever badge plate (BL only)
Y 3.3.2.3
L 3.3.2.1—(Center sill cars only —1 1/2 in.
minimum) Z 3.3.2.1—1 1/2 in. minimum
M 3.3.1.1—1 1/2 in. minimum AA 3.3.1.3, 6.0—commodity name
N 3.3.1.7—1 1/2 in. minimum 3.3.4.8—exemptions, safety permits, service

AB trials
Remarks (paragraph references are to this appendix):

a. For lined or coated tanks, see paragraph 3.3.1.5.
b. For painting, see paragraph 3.3.1.8.
c. When exterior heater coils are applied, see paragraph 3.3.1.9.
d. For CO2 stencils, see paragraph 3.3.1.12.
e. For leasing stencil, see paragraph 3.3.4.10.
f. For separate built dates of tank and underframe, stencil as shown. Otherwise, built date is part of consolidated
stencil. See paragraph 3.3.4.4 and paragraph 3.3.2.2.
g. Stencils are applied to both sides of car unless otherwise indicated.
h. Station stencil is required for retest dates. See paragraph 3.3.3.1.1.
i. For “inhalation hazard” stencil, see paragraph 3.3.1.13.
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.
Fig. C3 DOT and AAR stencil requirements for other tank cars* (concluded)
10/2007 C-III [M-1002] 167

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. C4 Manway style decal stencil
C-III [M-1002] 168 10/2007

M-1002 APPENDIX C
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. C5 Qualification stencil—blank

(see Fig. C8 for sample of completed stencil)
STATION STENCIL QUALIFIED DUE

TANK QUALIFICATION
THICKNESS TEST
SERVICE EQUIPMENT
PRD:
LINING
88.B.2 INSPECTION
STUB SILL INSPECTION
Fig. C6 Qualification stencil—shown with added lines for additional information

(reference paragraph 3.3.4.11 above)
10/2007 C-III [M-1002] 169

APPENDIX C M-1002

TANK QUALIFICATION 3.3.3.1.1 3.3.3.1.1 3.3.3.1.1
THICKNESS TEST 3.3.3.1.2 3.3.3.1.2 3.3.3.1.2
SERVICE EQUIPMENT 3.3.3.2.1 3.3.3.2.1 3.3.3.2.1
PRD:3.3.3.2.2 3.3.3.2.2.1 3.3.3.2.2.2 3.3.3.2.2.2 3.3.3.2.2.2
3.3.3.2.3 3.3.3.2.4 3.3.3.2.3.1 3.3.3.2.3.1 3.3.3.2.3.1
LINING 3.3.3.3 3.3.3.3 3.3.3.3
88.B.2 INSPECTION 3.3.3.4 3.3.3.4 3.3.3.4
STUB SILL INSPECTION 3.3.3.5 3.3.3.5 3.3.3.5
Fig. C7 Qualification stencil—shown 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. C8 Qualification stencil—sample of completed form
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
6 1--- ″
88.B.2 INSPECTION 2″ 2
STUB SILL INSPECTION 2″
Fig. C9 Qualification stencil—blank

This is an alternative to Fig. C5 for tank cars with an inner tank
(see Fig. C8 for sample of completed stencil with the exception
of the additional tank and thickness)
C-III [M-1002] 170 10/2007
M-1002 APPENDIX D
APPENDIX D
RETEST AND QUALIFICATION REQUIREMENTS
CONTENTS

2.0 Qualification and Maintenance Requirements for DOT Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . C-III–172
2.1 AAR Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–176
3.0 AAR Maintenance and Qualification Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–182
3.1 Supplemental AAR Maintenance and Qualification Requirements. . . . . . . . . . . . . . . . . . . . . . . . . C-III–182
3.2 Valves and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–184
3.3 Certificate of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–186
3.4 Elastomeric Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–186
3.5 Retest or Qualification Stencils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–186
3.6 Bottom Outlet Caps and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–186
3.7 Securement of Manway Covers, Protective Housings, Valves, and Fittings for Pressure and
Nonpressure Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–187
3.8 Placard Holder Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–188
4.0 Pressure Relief Valve and Hydrostatic Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–188
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–188
4.2 Hydrostatic Tank Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–188
4.3 Procedure for Retesting Pressure Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–191
4.4 Procedure for Retest of Interior Heater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–191
4.5 Test Gauge Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–192
5.0 Certificate of Test Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–194
6.0 Hinged and Bolted Manway Cover Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–198
6.1 Manway Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–198
6.2 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–198
6.3 Manway Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–198
6.4 Eyebolts and Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–198
6.5 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–199
6.6 Tightening of Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–199
10/2007 C-III [M-1002] 171

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. For the convenience of the reader, CFR Parts 180.501 through
180.517 are reproduced from Bureau of Explosives Tariff No.BOE6000-AA in effect August 29,
2007.
April 2007 §180.417—§180.507
Subpart F
QUALIFICATION AND MAINTENANCE OF TANK CARS
§180.501@Applicability. (a) This subpart prescribes require- for service provided they conform to all applicable safety requirements
ments, in addition to those contained in parts 107, 171, 172, 173, and of this subchapter:
179 of this subchapter, applicable to any person who manufactures,
fabricates, marks, maintains, repairs, inspects, or services tank cars Specification prescribed in the current
to ensure continuing qualification. regulations Other specifications permitted Notes
(b) Any person who performs a function prescribed in this part shall 105A200W 105A100W 1
perform that function in accordance with this part. 105A200ALW 105A100ALW 1
105A300W ICC-105, 105A300.
§180.503@Definitions. The definitions contained in §§171.8 and
179.2 of this subchapter apply. 105A400W 105A400
105A500W 105A500
§180.505@Quality assurance program. The quality assurance pro- 105A600W 105A600
gram requirements of §179.7 of this subchapter apply. 106A500X ICC-27, BE-27, 106A500
§180.507@Qualification of tank cars. (a) Each tank car marked 106A800X 106A800
as meeting a “DOT” specification or any other tank car used for the 107A * * * * 2
transportation of a hazardous material must meet the requirements of Note 1: Tanks built as Specification DOT 105A100W or DOT 105A100ALW may be altered
this subchapter or the applicable specification to which the tank was and converted to DOT 105A200W and DOT 105A200ALW, respectively.
constructed. Note 2: The test pressures of tanks built in the United States between January 1, 1941
and December 31, 1955, may be increased to conform to Specification 107A. Original and
(b) Tank car specifications no longer authorized for construc- revised test pressure markings must be indicated and may be shown on the tank or on a
tion. (1) Tank cars prescribed in the following table are authorized plate attached to the bulkhead of the car. Tanks built before 1941 are not authorized.
637
C-III [M-1002] 172 10/2007

M-1002 APPENDIX D
§180.507—§180.509 April 2007
(2) For each tank car conforming to and used under an exemption (iii) For lined or coated tank cars transporting a material corrosive
issued before October 1, 1984, which authorized the transportation to the tank, every 10 years for the tank, 5 years for the service
of a cryogenic liquid in a tank car, the owner or operator shall remove equipment.
the exemption number stenciled on the tank car and stamp the tank (A) When a lining or coating is applied to protect the tank
car with the appropriate Class DOT—113 specification followed by shell from the lading, the owner of the lining or coating shall
the applicable exemption number. For example: DOT—113D60W— determine the periodic inspection interval, test technique,
E * * * * (asterisks to be replaced by the exemption number). The and acceptance criteria for the lining or coating. The owner
owner or operator marking a tank car in this manner shall retain on must maintain at its principal place of business all support-
file a copy of the last exemption in effect during the period the tank ing documentation used to make such a determination,
car is in service. No person may modify a tank car marked under this such as the lining or coating manufacturer’s recom-
paragraph unless the modification is in compliance with an applicable mended inspection interval, test technique, and accept-
requirement or provision of this subchapter. ance criteria. The supporting documentation must be
(3) Specification DOT—113A175W, DOT—113C60W, DOT— made available to FRA upon request.
113D60W, and DOT—113D120W tank cars may continue in use, but (B) The owner of the lining or coating shall provide the periodic
new construction is not authorized. inspection interval, test technique, and acceptance crite-
(4) Class DOT 105A and 105S tank cars used to transport hydrogen ria for the lining or coating to the person responsible for
chloride, refrigerated liquid under the terms of DOT—E 3992 may qualifying the lining and coating.
continue in service, but new construction is not authorized. (d) Visual inspection. At a minimum, each tank car facility must
(5) Specification DOT–103A–ALW, 103AW, 103ALW, 103ANW, visually inspect the tank externally and internally as follows:
103BW, 103CW, 103DW, 103EW, and 104W tank cars may continue (1) An internal inspection of the tank shell and heads for abrasion,
in use, but new construction is not authorized. corrosion, cracks, dents, distortions, defects in welds, or any other
condition that makes the tank car unsafe for transportation, and except
in the areas where insulation or a thermal protection system precludes
§180.509@Requirements for inspection and test of specification
it, an external inspection of the tank shell and heads for abrasion,
tank cars. (a) General. (1) Each tank car facility shall evaluate a
corrosion, cracks, dents, distortions, defects in welds, or any other
tank car according to the requirements specified in §180.511.
condition that makes the tank car unsafe for transportation;
(2) Each tank car that successfully passes a periodic inspection
(2) An inspection of the piping, valves, fittings, and gaskets for
and test must be marked as prescribed in §180.515.
indications of corrosion and other conditions that make the tank car
(3) A written report as specified in §180.517(b) must be prepared
unsafe for transportation;
for each tank car that is inspected and tested under this section.
(3) An inspection for missing or loose bolts, nuts, or elements that
(b) Conditions requiring inspection and test of tank cars.
make the tank car unsafe for transportation;
Without regard to any other periodic inspection and test require-
(4) An inspection of all closures on the tank car for proper secure-
ments, a tank car must have an appropriate inspection and test
ment in a tool tight condition and an inspection of the protective
according to the type of defect and the type of maintenance or
housings for proper securement;
repair performed if:
(5) An inspection of excess flow valves having threaded seats for
(1) The tank car shows evidence of abrasion, corrosion, cracks,
tightness; and
dents, distortions, defects in welds, or any other condition that makes
(6) An inspection of the required markings on the tank car for legi-
the tank car unsafe for transportation. An example is if maintenance
bility.
is performed to replace a fitting, then only a leakage pressure test
(e) Structural integrity inspections and tests. At a minimum,
needs to be performed.
each tank car facility shall inspect the tank car for structural integrity
(2) The tank car was in an accident and damaged to an extent that
as specified in this section. The structural integrity inspection and
may adversely affect its capability to retain its contents.
test shall include all transverse fillet welds greater than 0.64 cm
(3) The tank bears evidence of damage caused by fire. (0.25 inch) within 121.92 cm (4 feet) of the bottom longitudinal
(4) The Associate Administrator for Safety, FRA, requires it based center line; the termination of longitudinal fillet welds greater than
on the existence of probable cause that a tank car or a class or design 0.64 cm (0.25 inch) within 121.92 cm (4 feet) of the bottom
of tank cars may be in an unsafe operating condition. longitudinal center line; and all tank shell butt welds within 60.96
(c) Frequency of inspection and tests. Each tank car shall have cm (2 feet) of the bottom longitudinal center line by one or more
an inspection and test according to the requirements of this paragraph. of the following inspection and test methods to determine that the
(1) For Class 107 tank cars and tank cars of riveted construction, the welds are in proper condition:
tank car must have a hydrostatic pressure test and visual inspection (1) Dye penetrant test;
conforming to the requirements in effect prior to July 1, 1996, for the (2) Radiography test;
tank specification. (3) Magnetic particle test;
(2) For Class DOT 113 tank cars, see §173.319(e) of this sub- (4) Ultrasonic test; or
chapter. (5) Optically-aided visual inspection (e.g., magnifiers, fiberscopes,
(3) For fusion welded tank cars, each tank car must have an inspec- borescopes, and machine vision technology).
tion and test in accordance with paragraphs (d) through (k) of this (f) Thickness tests. (1) Each tank car facility shall measure the
section. thickness of the tank car shell, heads, sumps, domes, and nozzles
(i) For cars transporting materials not corrosive to the tank, every on each tank car by using a device capable of accurately measuring
10 years for the tank and service equipment (i.e., filling and the thickness to within ⫾0.05 mm (⫾0.002 inch).
discharge, venting, safety, heating, and measuring devices). (2) After repairs, alterations, conversions or modifications of a tank
(ii) For non-lined or non-coated tank cars transporting materials car that result in a reduction to the tank car shell thickness, the tank
corrosive to the tank, an interval based on the following formula, car facility shall measure the thickness of the tank car shell in the area
but in no case shall the interval exceed 10 years for the tank of reduced shell thickness to ensure that the shell thickness conforms
and 5 years for service equipment: to paragraph (g) of this section.
(g) Service life shell thickness allowance. (1) A tank car found
t 1 − t2
i= with a shell thickness below the required minimum thickness after
r forming for its specification, as stated in part 179 of this subchapter,
may continue in service if:
Where: (i) Construction of the tank car shell and heads is from carbon
i is the inspection and test interval. steel, stainless steel, aluminum, nickel, or manganese-molyb-
t1 is the actual thickness. denum steel; and
t2 is the allowable minimum thickness under paragraph (g) (ii) Any reduction in the required minimum thickness of the tank
of this section. shell or head is not more than that provided in the following
r is the corrosion rate per year. table:
638
10/2007 C-III [M-1002] 173

APPENDIX D M-1002
April 2007 §180.509—§180.515
ALLOWABLE SHELL THICKNESS REDUCTIONS

Class DOT 103, 104, 111, and 115 tank cars Class DOT 105, 109, 112, and 114 tank cars
Damage type Top shell and tank head Bottom shell Top shell and tank head Bottom shell
Corrosion 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 0.79 mm (0.031 inch) 0.79 mm (0.031 inch)
Corrosion and mechanical 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 0.79 mm (0.031 inch) 0.79 mm (0.031 inch)
Corrosion, local 4.76 mm (0.188 inch) 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 1.58 mm (0.063 inch)
Mechanical, local 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 1.58 mm (0.063 inch) 1.58 mm (0.063 inch)
Corrosion and mechanical, local 4.76 mm (0.188 inch) 3.17 mm (0.125 inch) 1.58 mm (0.063 inch) 1.58 mm (0.063 inch)
Notes:
1. The perimeter for a local reduction may not exceed a 60.96 cm (24 inch) perimeter. Local reductions in the top shell must be separated from other reductions in the top shell by at
least 40.64 cm (16 inches). The cumulative perimeter for local reductions in the bottom shell may not exceed 182.88 cm (72 inches).
2. Any reduction in the tank car shell may not affect the structural strength of the tank car so that the tank car shell no longer conforms to Section 6.2 of the AAR Specifications for Tank
Cars (IBR, see §171.7 of this subchapter).
3. Any reduction applies only to the outer shell for Class DOT 115 tank cars.
4. For Class DOT 103 and 104 tank cars, the inside diameter may not exceed 243.84 cm (96 inches).
(h) Safety system inspections. At a minimum, each tank car facil- (a) Visual inspection. A tank car successfully passes the visual
ity must inspect: inspection when the inspection shows no structural defect that may
(1) Tank car thermal protection systems, tank head puncture resis- cause leakage from or failure of the tank before the next inspection
tance systems, coupler vertical restraint systems, and systems used and test interval.
to protect discontinuities (i.e., skid protection and protective housings) (b) Structural integrity inspection and test. A tank car success-
to ensure their integrity. fully passes the structural integrity inspection and test when it shows
(2) Reclosing pressure relief devices by: no structural defect that may initiate cracks or propagate cracks and
(i) Removing the reclosing pressure relief device from the tank cause failure of the tank before the next inspection and test interval.
car for inspection; and (c) Service life shell thickness. A tank car successfully passes
(ii) Testing the reclosing pressure relief device with air or another the service life shell thickness inspection when the tank shell and
gas to ensure that it conforms to the start-to-discharge pressure heads show no thickness reduction below that allowed in §180.509(g).
for the specification or hazardous material in this subchapter. (d) Safety system inspection. A tank car successfully passes the
(i) Lining and coating inspection and test. When this subchapter safety system inspection when each thermal protection system, tank
requires a lining or coating, at a minimum, each tank car facility must head puncture resistance system, coupler vertical restraint system,
inspect the lining or coating installed on the tank car according to the and system used to protect discontinuities (e.g., breakage grooves
inspection interval test technique, and acceptance criteria established on bottom outlets and protective housings) on the tank car conform
by the owner of the lining or coating in accordance with paragraph to this subchapter.
(c)(3)(iii) of this section. (e) Lining and coating inspection. A tank car successfully passes
(j) Leakage pressure test. (1) After reassembly of a tank car or the lining and coating inspection and test when the lining or coating
service equipment, a tank car facility must perform a leak test on the conforms to the owner’s acceptance criteria.
tank or service equipment to detect leakage, if any, between manway (f) Leakage pressure test. A tank car successfully passes the
covers, cover plates, and service equipment. The test may be con- leakage pressure test when all product piping, fittings and closures
ducted with the hazardous material in the tank. When the test pressure show no indication of leakage.
exceeds the start-to-discharge or burst pressure of a pressure relief
(g) Hydrostatic test. A Class 107 tank car or a riveted tank car
device, the device must be rendered inoperative. The written proce-
successfully passes the hydrostatic test when it shows no leakage,
dures and test method for leak testing must ensure for the sensitivity
distortion, excessive permanent expansion, or other evidence of weak-
and reliability of the test method and for the serviceability of compo-
ness that might render the tank car unsafe for transportation service.
nents to prevent premature failure.
(2) Interior heater systems must be tested hydrostatically at 13.87
Bar (200 psig) and must show no signs of leakage. §180.513@Repairs, alterations, conversions, and modifica-
(k) Alternative inspection and test procedures. In lieu of the tions.
other requirements of this section, a person may use an alternative (a) In order to repair tank cars, the tank car facility must comply
inspection and test procedure or interval based on a damage-toler- with the requirements of appendix R of the AAR Specifications for
ance fatigue evaluation (that includes a determination of the probable Tank Cars (IBR, see §171.7 of this subchapter).
locations and modes of damage due to fatigue, corrosion, or acciden-
(b) Unless the exterior tank car shell or interior tank car jacket has
tal damage), when the evaluation is examined by the Association
a protective coating, after a repair that requires the complete removal
of American Railroads Tank Car Committee and approved by the
of the tank car jacket, the exterior tank car shell and the interior tank
Associate Administrator for Safety, FRA.
car jacket must have a protective coating applied to prevent the
(l) Inspection and test compliance date for tank cars. (1) After
deterioration of the tank shell and tank jacket.
July 1, 2000, each tank car with a metal jacket or with a thermal
protection system shall have an inspection and test conforming to this
section no later than the date the tank car requires a periodic hydro- §180.515@Markings. (a) When a tank car passes the required in-
static pressure test (i.e., the marked due date on the tank car for the spection and test with acceptable results, the tank car facility shall
hydrostatic test). mark the date of the inspection and test and the due date of the next
(2) After July 1, 1998, each tank car without a metal jacket shall inspection and test on the tank car in accordance with appendix
have an inspection and test conforming to this section no later than C of the AAR Specifications for Tank Cars (IBR, see §171.7 of this
the date the tank car requires a periodic hydrostatic pressure test subchapter). When a tank car facility performs multiple inspection and
(i.e., the marked due date on the tank car for the hydrostatic test). test at the same time, one date may be used to satisfy the requirements
(3) For tank cars on a 20-year periodic hydrostatic pressure test of this section. One date also may be shown when multiple inspection
interval (i.e., Class DOT 103W, 104W, 111A60W1, 111A100W1, and and test have the same due date.
111A100W3 tank cars), the next inspection and test date is the mid- (b) Pressure converted tank cars must have the new specification
point between the compliance date in paragraph (l)(1) or (2) of this and conversion date permanently marked in letters and figures at
section and the remaining years until the tank would have had a least 0.95 cm (0.375 inch) high on the outside of the manway nozzle
hydrostatic pressure test. or the edge of the manway nozzle flange on the left side of the car.
The marking may have the last numeral of the specification number
§180.511@Acceptable results of inspections and tests. Provided omitted (e.g., “DOT 111A100W” instead of “DOT 111A100W1”).
it conforms with other applicable requirements of this subchapter, a (c) When pressure tested within six months of installation and pro-
tank car is qualified for use if it successfully passes the following tected from deterioration, the test date marking of a reclosing pressure
inspections and tests conducted in accordance with this subpart: relief device is the installation date on the tank car.
639
C-III [M-1002] 174 10/2007

M-1002 APPENDIX D
§180.517—§180.519 April 2007
§180.517@Reporting and record retention requirements. single-unit tank car tanks. (a) General. Unless otherwise provided
(a) Certification and representation. Each owner of a specifica- in this subpart, tanks designed to be removed from cars for filling and
tion tank car shall retain the certificate of construction (AAR Form 4– emptying and tanks built to a Class DOT 107A specification and their
2) and related papers certifying that the manufacture of the specifica- safety relief devices must be retested periodically as specified in
tion tank car identified in the documents is in accordance with the Retest Table 1 of paragraph (b)(5) of this section. Retests may be
applicable specification. The owner shall retain the documents made at any time during the calendar year the retest falls due.
throughout the period of ownership of the specification tank car and (b) Pressure test. (1) Each tank must be subjected to the specified
for one year thereafter. Upon a change of ownership, the requirements hydrostatic pressure and its permanent expansion determined. Pres-
in Section 1.3.15 of the AAR Specifications for Tank Cars (IBR, see sure must be maintained for 30 seconds and for as long as necessary
§171.7 of this subchapter) apply. to secure complete expansion of the tank. Before testing, the pressure
(b) Inspection and test reporting. Each tank car that is inspected gauge must be shown to be accurate within 1 percent at test measure.
as specified in §180.509 must have a written report, in English, pre- The expansion gauge must be shown to be accurate, at test pressure,
pared according to this paragraph. The owner must retain a copy of to within 1 percent. Expansion must be recorded in cubic centimeters.
the inspection and test reports until successfully completing the next Permanent volumetric expansion may not exceed 10 percent of total
inspection and test of the same type. The inspection and test report volumetric expansion at test pressure and the tank must not leak or
must include the following: show evidence of distress.
(1) Type of inspection and test performed (a checklist is acceptable); (2) Each tank, except tanks built to specification DOT 107A, must
(2) The results of each inspection and test performed; also be subjected to interior air pressure test of at least 100 psig
(3) Owner’s reporting mark; under conditions favorable to detection of any leakage. No leaks may
(4) DOT Specification; appear.
(5) Inspection and test date (month and year); (3) Safety relief valves must be retested by air or gas, must start-
(6) Location and description of defects found and method used to to-discharge at or below the prescribed pressure and must be vapor
repair each defect; tight at or above the prescribed pressure.
(7) The name and address of the tank car facility and the signature (4) Rupture discs and fusible plugs must be removed from the tank
of inspector. and visually inspected.
(5) Tanks must be retested as specified in Retest Table 1 of this
paragraph (b)(5), and before returning to service after repairs involving
§180.519@Periodic retest and inspection of tank cars other than welding or heat treatment:
RETEST TABLE 1
Retest interval—years Minimum Retest pressure—psig Pressure relief valve pressure—psig
Specification Tank Pressure relief devicesd Tank hydrostatic expansionc Tank air test Start-to-discharge Vapor tight
DOT 27 5 2 500 100 375 300
106A500 5 2 500 100 375 300
106A500X 5 2 500 100 375 300
106A800 5 2 800 100 600 480
106A800X 5 2 800 100 600 480
106A800NCl 5 2 800 100 600 480

d a
107A * * * * 5 2 (b) None None None
110A500—W 5 2 500 100 375 300
110A600—W 5 2 600 100 500 360
110A800—W 5 2 800 100 600 480
110A1000—W 5 2 1,000 100 750 600
BE—27 5 2 500 100 375 300
Notes:
a
If DOT 107A * * * * tanks are used for transportation of flammable gases, one rupture disc from each car must be burst at the interval prescribed. The sample disc must burst at a
pressure not exceeding the marked test pressure of the tank and not less than 70 percent of the marked test pressure. If the sample disc does not burst within the prescribed limits, all
discs on the car must be replaced.
b
The hydrostatic expansion test pressure must at least equal the marked test pressure.
c
See §180.519(b)(1).
d
Safety relief valves of the spring-loaded type on tanks used exclusively for fluorinated hydrocarbons and mixtures thereof which are free from corroding components may be retested
every 5 years.
(6) The month and year of test, followed by a “V” if visually inspected in accordance with the criteria in CGA C–6 (IBR, see §171.7 of this
as described in paragraph (c) of this section, must be plainly and subchapter).
permanently stamped into the metal of one head or chime of each (d) Written records. The results of the pressure test and visual
tank with successful test results; for example, 01–90 for January 1990. inspection must be recorded on a suitable data sheet. Completed
On DOT 107A * * * * tanks, the date must be stamped into the metal copies of these reports must be retained by the owner and by the
of the marked end, except that if all tanks mounted on a car have person performing the pressure test and visual inspection as long
been tested, the date may be stamped into the metal of a plate as the tank is in service. The information to be recorded and
permanently applied to the bulkhead on the “A” end of the car. Dates checked on these data sheets are: Date of test and inspection;
of previous tests and all prescribed markings must be kept legible. DOT specification number; tank identification (registered symbol
and serial number, date of manufacture and ownership symbol);
(c) Visual inspection. Tanks of Class DOT 106A and DOT 110A– type of protective coating (painted, etc., and statement as to need
W specifications (Sec. §179.300 and 179.301 of this subchapter) used for refinishing or recoating); conditions checked (leakage, corrosion,
exclusively for transporting fluorinated hydrocarbons and mixtures gouges, dents or digs, broken or damaged chime or protective
thereof, and that are free from corroding components, may be given ring, fire, fire damage, internal condition); test pressure; results of
a periodic complete internal and external visual inspection in place tests; and disposition of tank (returned to service, returned to
of the periodic hydrostatic retest. Visual inspections shall be made manufacturer for repair, or scrapped); and identification of the
only by competent persons. The tank must be accepted or rejected person conducting the retest or inspection.
640
10/2007 C-III [M-1002] 175

APPENDIX D M-1002
2.1 AAR Tank Car Tanks

2.1.1 Applicability
This program establishes the minimum acceptable framework for an owner's qualification pro-
gram 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 instruc-
tions), as required by 49 CFR 179.7(d), for use by tank car facility employees. The owner's qualifi-
cation 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 owner's 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 func-
tion in accordance with this program.
2.1.2 Definitions
Table D1. General definitions
Bottom shell That portion of a tank car tank surface, excluding the head ends of
the tank, that lies within 2 ft, measured circumferentially, of the
bottom longitudinal centerline of the tank car tank.
Design level of The level of reliability that is built into the tank car. Therefore, it
reliability and safety is inherent in its specification, design, and manufacture.
Interior heater system A piping system that uses a fluid medium to heat the lading
within the tank for the purposes of unloading.
Lining/coating owner The party responsible for bearing the cost of the maintenance of
the lining or coating.
Maintenance Inspection, upkeep, or preservation, including ordinary repairs
necessary and proper from time to time.
Qualification A periodic examination, based on a written program, to verify con-
formance to this appendix, followed by a representation of con-
formance to the specification.
Reliability The quantified ability of a structure to be used in a known envi-
ronment without failure for a specified period.
Representation Certifying in writing or marking on the tank car tank, jacket, or an
associated document, indicating compliance with the specification.
Safety system Coupler vertical restraint systems, and systems used to protect
discontinuities.
Service equipment Equipment used for filling, sampling device, emptying, venting,
vacuum relief, pressure relief, heating (if internal to the tank),
lading temperature measurement, or measuring the amount of
lading within the tank.
Tank car owner The entity identified in UMLER through the owner's marks.
Top shell The tank car tank surface, excluding the head ends and bottom
shell of the tank car tank.
Valve or fitting owner The party responsible for bearing the cost of the maintenance of
the valve or fitting.
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M-1002 APPENDIX D
2.1.3 Quality Assurance Program

The quality assurance program requirements of the AAR Manual of Standards and Recommended
Practices, Section J, Specification M-1003, apply.
2.1.4 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
2.1.5 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.
2.1.6 Frequency of Qualification
2.1.6.1 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.
2.1.6.2 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.
2.1.6.3 Tank cars with fusion welds must be qualified and maintained in accordance with Table
D2. All qualification requirements need not be done at the same time.
Table D2. Frequency of qualification

Retest and Qual-
ification Re- Description Maximum Interval
quirements
2.1.7 Visual inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 years
2.1.8 Structural integrity inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 years
2.1.9 and 2.1.10 Thickness test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See paragraph 2.1.9
2.1.11 Safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 years
2.1.12 Lining or coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Per owner’s program
2.1.13 Leakage pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After reassembly
2.1.14 Service equipment (including pressure relief devices) . . . . . . . . . . . . . . . 10 years
2.1.7 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:
2.1.7.1 Except in areas where insulation or internal coatings 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.
2.1.7.2 Non-coated tank cars shall have a visual inspection at the time of the tank qualification.
10/2007 C-III [M-1002] 177

APPENDIX D M-1002
2.1.7.3 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.
2.1.7.4 An inspection of the service equipment, in accordance with the owner’s maintenance pro-
gram, for indications of conditions that could make the tank car unsafe for transportation.
2.1.7.5 An inspection for missing or loose bolts, nuts, and other fasteners that could make the
tank car unsafe for transportation.
2.1.7.6 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.
2.1.7.7 An inspection of the required markings for legibility.
2.1.8 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:
2.1.8.1 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.
2.1.8.2 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.
2.1.8.3 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.
2.1.8.4 The owner must maintain all supporting documentation used to make such determina-
tion at its principal place of business and make the data available to AAR and FRA upon request.
2.1.8.5 For Class AAR-206 tanks, paragraphs 2.1.8.1, 2.1.8.2 and 2.1.8.3 apply only to the outer
shell fillet welds and to the (non-reinforced) exposed outer shell butt welds.
2.1.8.6 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
2.1.8.7 Perform weld inspection per the requirements of paragraph 3.1.2.1 below.
2.1.8.8 Perform truck and draft component inspection per the requirements of paragraph 3.1.2.2
below.
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M-1002 APPENDIX D
2.1.9 Thickness Tests

2.1.9.1 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).
2.1.9.2 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. D1 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 2.1.10 below).
D = Condemning limit for general corrosion (required minimum shell or head thickness, minus the table
value in paragraph 2.1.10 below).
E = Condemning limit for localized corrosion [required minimum shell or head thickness, minus the table
value in paragraph 2.1.10 below, minus 1/16-in. (1.58 mm)]. See Note 1 in paragraph 2.1.10 below for
diameter limitations and minimum separation distances.
F = Allowable shell thickness reduction (table value in paragraph 2.1.10 below).
G = Additional thickness reduction for localized areas.
2.1.9.2.1 For tank cars with a lining/coating program, thickness testing is not required. The lin-
ing/coating program must include a documented inspection procedure.
2.1.9.3 For a localized repair of an internal lining or internal coating, a qualified individual shall
verify conformance with paragraph 2.1.10 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.
2.1.9.4 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. D1 of
this paragraph.
2.1.9.5 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 prin-
cipal place of business documentation describing the allowable thickness reductions for sumps,
domes, nozzles, and nozzle reinforcements. This documentation must be available to AAR/FRA
upon request.
2.1.9.6 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 2.1.10.
10/2007 C-III [M-1002] 179

APPENDIX D M-1002
2.1.10 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 pro-
vided in the following table.
Table D3. 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 PARAGRAPH 6.2 OF THIS AAR SPECIFICATION FOR TANK CARS.
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.
2.1.11 Safety System Inspection

Each tank car owner shall ensure qualification of the tank car safety systems.
2.1.12 Lining and Coating Inspection and Test
All interior linings and/or coatings shall be inspected per the lining or coating owner’s written pro-
gram.
2.1.13 Leakage Pressure Test
2.1.13.1 Unless the design of the service equipment arrangement precludes it (e.g., there is no fit-
ting to pressurize the tank), each tank car facility shall ensure that tank, service equipment, and
closures installed on the tank are leak tested.
2.1.13.2 The test may be conducted with the lading in the tank.
2.1.13.3 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.
2.1.13.4 This section does not apply to facilities that remove closures for the sole purpose of load-
ing or unloading the lading (e.g., blind flanges, pipe plugs, quick-disconnects, etc.).
2.1.14 Service Equipment Inspection and Test
2.1.14.1 Each tank car owner shall ensure that qualification of tank car service equipment is per-
formed at least once every 10 years.
2.1.14.2 Each tank car facility shall qualify service equipment, including reclosing pressure relief
devices and interior heater systems, in accordance with this appendix.
2.1.15 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).
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M-1002 APPENDIX D
2.1.16 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:
2.1.16.1 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.
2.1.16.2 Structural integrity inspection and test: A tank car successfully passes the struc-
tural 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.
2.1.16.3 Service life shell thickness: A tank car successfully passes the service-life shell thick-
ness inspection when the tank shell and heads show no thickness reduction below that allowed in
paragraph 2.1.10 above.
2.1.16.4 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.
2.1.16.5 Lining and coating inspection: Per owner’s written program.
2.1.16.6 Leakage pressure test: A tank car successfully passes the leakage pressure test when
all product piping, fittings, and closures show no indication of leakage.
2.1.16.7 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.
2.1.17 Repairs, Alterations, Conversions, Modifications, and Maintenance
2.1.17.1 All work must be performed in facilities having the appropriate level of AAR certification
and must comply with all applicable requirements of M-1002.
2.1.17.2 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.
2.1.18 Markings
When a tank car passes the required inspection and test with acceptable results, the tank car facil-
ity shall mark the date qualified and the next qualification date (due date) on the tank car in
accordance with Appendix C.
2.1.19 Reporting and Record Retention Requirements
2.1.19.1 Each owner of a specification tank car shall retain the certificate of construction (AAR
Form 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.
2.1.19.2 The builder's 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.
2.1.19.3 The builder must retain the inspection and test reports to affirm that the tests and
inspections required under this specification were performed.
2.1.19.4 The owner shall retain the documents throughout the period of ownership.
2.1.19.5 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
2.1.20 Inspection and Test Reporting

2.1.20.1 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.
2.1.20.2 The owner must retain a copy of the inspection and test reports until successfully com-
pleting 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, CGSB 43 Part III, and DOT-E 12095.
3.1 Supplemental AAR Maintenance and Qualification Requirements
3.1.1 These supplemental requirements apply to all railroad tank cars marked to indicate compli-
ance 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 0.64 cm (0.25 in.) within
121.92 cm (4 ft) of the bottom longitudinal centerline;
• The termination of longitudinal fillet welds with design dimensions greater than 0.64 cm
(0.25 in.) within 121.92 cm (4 ft) of the bottom longitudinal center line; and
• The tank shell butt welds within 60.96 cm (2 ft) 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 of the bolsters. 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 D4.
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
T1. 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.
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M-1002 APPENDIX D
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 D4. Required tank car qualifications/inspections
Where Required Description Maximum Interval
DOT-E12095 or
180.509(d) Visual inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 years
DOT-E12095 or
180.509(e) Structural integrity inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 years
DOT-E12095 or
180.509(f) Thickness test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 180.509(f)
DOT-E12095 or
180.509(h) Safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 years
DOT-E12095 or
180.509(i) Lining or coating (for materials corrosive to the tank). . . . . . . . . . . . . . . . See 180.509(i)
DOT-E12095 or
180.509(j) Leakage pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After assembly
DOT-E12095 or
180.509(c) Service equipment (including pressure relief devices) . . . . . . . . . . . . . . . See 180.509(c)
Trucks, draft components, center plate, side sills, end sills, side bearings
Field Manual (including proper adjustment), and body bolsters. On jacketed cars,
Rule 88.B.2 inspect portions of the bolster visible without disturbing the jacket. . 10 years
AAR Circular At tank qualification or
CPC-1094 Stub draft sills, sill pads, sill attachments welds (outboard of bolsters) . . mileage limit
AAR M-1002
Appendix D With structural integrity
paragraph 3.1.1.4 Stub draft sills, sill pads, sill attachments welds (inboard of bolsters) . . . inspection
10/2007 C-III [M-1002] 183

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 Definitions—General
Table D5. General definitions

Visual An inspection of valves, fittings, and closures, without disassem-
bly, for obvious signs of defects.
Bench Test A leak test of a valve or fitting mounted on a test fixture to deter-
mine pressure retention 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.
Leak Test A leak test of the installed valve or fitting performed below the
tank test pressure.
• 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 fit-
ting and the tank, to determine pressure retention integ-
rity 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 deter-
mine the integrity of the fluid seal joint between a pres-
sure 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.
C-III [M-1002] 184 10/2007

M-1002 APPENDIX D
3.2.2 Definitions—Levels of Maintenance
Reseal A disassembly of a valve or fitting as necessary to access resilient

components, followed by an inspection of the sealing surfaces,
replacement of resilient components, and reassembly of the valve
or fitting.
Rebuild A complete disassembly of a valve or fitting to inspect the pres-
sure-containing and operating components for noticeable defects,
cleaning as necessary, restoration of components that have notice-
able indications of defects, and replacement of all resilient compo-
nents. See Appendix A, paragraph 4.11.1, for maintenance
limitations.
Remanufacture Performed only by, or with approval of, the original equipment
manufacturer (OEM), 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 specifica-
tion.
3.2.3 Maintenance and Qualification of Valves and Fittings
3.2.3.1 Each valve and fitting owner is responsible for the development or adoption of a mainte-
nance and qualification program to ensure that valve and fittings meet a performance specifica-
tion.
When cracked pressure relief valve stems or springs are found during maintenance or qualifica-
tion 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.
3.2.3.2 Maintenance procedures for valves and fittings must include the following elements:
• Work instructions to include 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)
3.2.3.3 In addition to paragraph 3.2.3.2, 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.
10/2007 C-III [M-1002] 185

APPENDIX D M-1002
3.2.3.4 Valves and fittings may be replaced in kind on tank cars without changing the qualifica-
tion dates marked on the tank when performed by a Class A through G facility. The facility replac-
ing 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. D2 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 tank or pressure relief valve qualification, all bottom outlet caps and nozzles
must have the threaded surfaces inspected for wear per the requirements of Appendix E, Figs. E18
through E18.5. Caps or nozzles worn beyond these limits must be removed from service. Typical
No–Go gauges are shown in Figs. E18.6 through E18.9. 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. E18.6 through E18.9.
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.
C-III [M-1002] 186 10/2007

M-1002 APPENDIX D
3.6.1.3 A single cap gasket of 1/4-in. (6.35-mm) maximum thickness must be used. Multiple gas-
kets 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 Pres-
sure 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 engage-
ments 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 fas-
teners 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
l e = l s – l a + t p + ------ (in.)
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, para-
graphs 1.2.3 and 4.2 (for pressure cars), or Appendix M, paragraph 4.3 (for nonpressure cars).
10/2007 C-III [M-1002] 187

APPENDIX D M-1002
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 Man-
ual 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 on file at AAR and will be published periodically by Circular Letter. Prior to authorizing work
at a facility not listed, contact the Executive Director—Tank Car Safety, Association of American
Railroads, 50 F Street N.W., Washington, D.C. 20001-1564 to determine if appropriate certification
of the facility will be in effect at the time of the performance of the work (phone 202-639-2147; fax
202-639-2930; email pkinnecom@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.
C-III [M-1002] 188 10/2007

M-1002 APPENDIX D
4.2.2 Steps Common to Both General Purpose Tanks and Pressure Car Tanks
Step Action
1. Determine the tank’s 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 appro-
priate 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 3.3.3.
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.
10/2007 C-III [M-1002] 189

APPENDIX D M-1002
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 pip-
ing, 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 3.2.3 above and Fig. D3.
9. Install valves and fittings to manway cover and tighten per paragraph 3.2.3 above.
10. Inspect valves and fittings for compliance with provisions of 49 CFR 179.100-17(a), and
Appendix A, paragraph 4.15.
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 re-
lease provisions of 49 CFR 179.201-6.
6. Tighten the manway cover per paragraph 3.2.3 above and Fig. D3, 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 4.15.
8. Perform the steps listed in paragraph 4.2.2 above, steps 17 through 19, to complete the
process.
C-III [M-1002] 190 10/2007

M-1002 APPENDIX D
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 manufacturer’s guidelines and replace unusable parts. Repair work
shall be limited per Appendix A, paragraph 4.11.
6. Elastomeric materials used for gaskets or gasket seals must be replaced. Observe dimen-
sional and compatibility provisions of paragraph 3.2 above.
7. Reassemble per manufacturer’s 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 D6,
the cause shall be determined and corrected and the valve retested.
13. Stencil cars as required in accord with Appendix C, paragraph 3.3.3.
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 3.3.3.
8. Complete documentation as required by DOT and send to the car owner.
10/2007 C-III [M-1002] 191

APPENDIX D M-1002
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 D6. Allowable pressure relief valve pressure tolerances
Maximum
Nominal Gauge
Tolerance Minimum Maximum Minimum Gauge
STDa/ (psig) Rangee/
b/ (+/-)c/ (psig) STD (psig) STDa/ (psig) VTPd/ (psig) Incremente/
(psig)
(psig)
35 3 32 38 28 0 – 100 1
75 3 72 78 60 0 – 150/160 1
150 4.5 145.5 154.5 120 0 – 300 2
225 6.75 218.25 231.75 180 0 – 400 5
247.5 7.4 240.1 254.9 196 0 – 400 5
255 7.7 247.3 262.7 204 0 – 400 5
280.5 8.4 272.1 288.9 224 0 – 500 5
300 9 291 309 240 0 – 500 5
330 10 320 340 264 0 – 500 5
375 11.25 363.75 386.25 300 0 – 600 10
450 13.5 436.5 463.5 360 0 – 750 10
For tank tests to 60 psig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 – 150/160 1
For tank tests above 60 psig to 200 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 – 400 5
For tank tests between 200 psig and 400 psig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 – 600 10
For tank tests over 400 psig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 – 1000 20
Internal Heater Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 – 400 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.
C-III [M-1002] 192 10/2007

M-1002 APPENDIX D
Fig. D3 Recommended sequence and tightening procedures for resecuring tank car tank manway covers, valves, fit-
tings, and flanges
10/2007 C-III [M-1002] 193

APPENDIX D M-1002
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 submit-
ted to and retained by the tank car owner. Submittal of the report may be on Fig. D4, 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:
C-III [M-1002] 194 10/2007

M-1002 APPENDIX D
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. D4, 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 re-
quirements 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 re-
duced vapor-tight pressure must be shown.
g. This item indicates whether or not the elastomeric valve seals have been replaced. En-
ter a yes or no.
h. If the answer to item g. is yes, indicate the material of construction of the new elasto-
meric seals.
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 3.3.3.2, for stenciling requirements for tank cars
equipped with combination pressure relief devices.
10/2007 C-III [M-1002] 195

APPENDIX D M-1002
Line Instruction
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 the form.
C-III [M-1002] 196 10/2007

M-1002 APPENDIX D
Certificate of Test Form

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 dis-
tress.
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. D4 Certificate of Test Form

10/2007 C-III [M-1002] 197
APPENDIX D M-1002
6.0 HINGED AND BOLTED 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
125-500 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 D7 through D12). Check cover for cen-
tering.
6.2 Gasket
Install a new gasket compatible with the commodity to be transported. Gasket size shall be as
specified by the car manufacturer on the applicable manway style chart (Tables D7 through D12).
As an alternative, manway nozzle rim style gaskets shown in Table D13 may be used, provided the
gasket seats and seals properly. Care shall be exercised to remove existing commodity, old gasket,
and gasket cement from gasket seating surfaces before carefully installing the new gasket.
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 sur-
face shall be smooth within 125–500 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.
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 replace-
ment.
6.4.2 Gauge the major diameter of the external eyebolt threads over the nut clamping surface
using a calibrated GO-NOGO 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 origi-
nal 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 pres-
sure.
C-III [M-1002] 198 10/2007

M-1002 APPENDIX D
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 car’s 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. D5 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.
10/2007 C-III [M-1002] 199

APPENDIX D M-1002
Table D7. Manway Style Chart for ACF Industries, Inc.a/

(page 1 of 3)
Nominal Dia./ Gasket Dimensions
Manway Style Gasket Type Diagramc/
Number of Boltsb/ (OD × ID × THbtK)
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 D13 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.
C-III [M-1002] 200 10/2007

M-1002 APPENDIX D

(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"
10/2007 C-III [M-1002] 201

APPENDIX D M-1002

(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 ——
C-III [M-1002] 202 10/2007

M-1002 APPENDIX D
Table D8. Manway Style Chart for General American Transportation Companya/
(page 1 of 3)
Number of Boltsb/ (OD × ID × THK)
Elastomeric 22 1/8" × 19" × 1/4" A

GATX #1 20"/6
Hard 22" × 19" × 1/4"
Elastomeric 22 1/8" × 19" × 1/4" A

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"
10/2007 C-III [M-1002] 203

APPENDIX D M-1002
(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"
Elastomeric 21 7/8" × 19" × 1/4" A

GATX #6 20"/8
Hard 21 5/8" × 19" × 1/4"
Elastomeric 19 1/2" × 17" × 1/4" A

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"
C-III [M-1002] 204 10/2007

M-1002 APPENDIX D
(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"
10/2007 C-III [M-1002] 205

APPENDIX D M-1002
Table D9. 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] 206 10/2007

M-1002 APPENDIX D
Table D10. 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"
10/2007 C-III [M-1002] 207

APPENDIX D M-1002
Table D11. 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] 208 10/2007

M-1002 APPENDIX D
(page 2 of 3)
Elastomeric 22 1/8" × 19" × 1/4" A

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
10/2007 C-III [M-1002] 209

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
C-III [M-1002] 210 10/2007

M-1002 APPENDIX D
Table D12. Manway Style Chart for AAR Standard Gasketsa/

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

See Figs. E26A, B, and C for typical
AAR-1 20"/6-8-10
manway cover gasket grooves.
Hard 21 5/8" × 19 1/2" × 1/8"
Table D13. Manway Style Chart for Alternate Manway Gasket Styles
Manway Style Gasket Type Diagramb/
Number of Boltsa/ (OD × ID × THK)
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.
10/2007 C-III [M-1002] 211

APPENDIX D M-1002
C-III [M-1002] 212 10/2007

M-1002 APPENDIX E
APPENDIX E
DESIGN DETAILS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–215
2.1 Dimensions and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–215
2.2 Tolerance for Single-Unit Tank Car Tank Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–216
2.3 Ellipsoidal Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–216
3.0 Reinforcement of Head and Shell Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–216
3.1 Acceptable Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–216
3.2 Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–216
3.3 Reinforcement Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–217
3.4 Dome Reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–217
3.5 Openings in Knuckle Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–217
3.6 Nozzle Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–218
4.0 Manway Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–218
4.1 Design—Covers for Pressure Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–218
4.2 Openings in Pressure Car Manway Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–219
4.3 Design—Covers for Nonpressure Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–219
4.4 Openings in Protective Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–220
4.5 Pressure Car Manway Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–220
5.0 Pressure Relief Device Connections for Nonpressure Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–221
5.1 Standard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–221
6.0 Joint Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–221
6.1 Joint Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–221
6.2 Plug Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–221
6.3 Design Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–222
6.4 Abutting Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–222
6.5 Transition Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–222
7.0 Compartment Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–223
7.1 Inserted Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–223
7.2 Compartments Constructed as Separate Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–223
8.0 Vertical Curve Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–224
9.0 Protection of Bottom Discontinuities on Class 105A, 109A, 112A, 114A, and 120A Tank Car Tanks C-III–225
10.0 Protection of Bottom and Top Discontinuities on Nonpressure Tank Car Tanks . . . . . . . . . . . . . . . . C-III–226
10.1 Bottom Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–226
10.2 Top Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–227
11.0 Noncircular Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–228
10/2007 C-III [M-1002] 213

APPENDIX E M-1002

12.0 Anchor Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–230
13.0 Head-to-Sill Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–231
14.0 Bottom Outlet Valve and Nozzle Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–231
15.0 Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–232
15.1 Requirements for Use of Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–232
15.2 Design of Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–232
16.0 Tank Bottom Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–232
C-III [M-1002] 214 10/2007

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.
2.0 DEFINITIONS
The definitions and abbreviations in Chapter 1, paragraph 1.2, apply in this appendix.
2.1 Dimensions and Tolerances
2.1.1 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.”
2.1.2 The following notes apply to illustrations in Figs. E5 through E13 and E19 through E19.25:
2.1.2.1 Unless otherwise specified, standard tolerances for decimal dimensions are ±0.005 in. and
standard tolerances for fractional dimensions are ±1/64 in.
2.1.2.2 Unless otherwise specified, the fit of screw threads is Class 2A and 2B (ANSI B1.1).
2.1.2.3 Standard tolerance on taper pipe threads is ±1 thread.
2.1.2.4 Engagement of taper pipe threads conforms to American Standard Taper Pipe Threads
(NPT) (ANSI B2.1).
Table E1. 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
2.1.2.5 Recommended drills for taps are as follows:
Table E2. 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.
2.1.2.6 Bolt holes are equally spaced ±1/64 in.
10/2007 C-III [M-1002] 215

APPENDIX E M-1002
2.1.2.7 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).
2.1.2.8 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.
2.1.3 The following notes apply to Figs. E18 through E18.9 for bottom outlet caps and nozzles:
2.1.3.1 The thread dimensions on the bottom outlet connections in Figs. E18 through E18.9 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.
2.1.3.2 To identify manufactured parts conforming with this standard, E18 is to be cast or steel
stamped on a surface not subject to wear.
2.2 Tolerance for Single-Unit Tank Car Tank Heads
2.2.1 The inner surface of a torispherical (flanged and dished) or ellipsoidal head must not devi-
ate 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.
2.2.2 Measurements for determining the tolerances must be taken from the surface of the base
metal and not from the welds.
2.2.3 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.
2.3 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 2.2 above are applied to the shape specified for a true ellipsoidal head.
3.0 REINFORCEMENT OF HEAD AND SHELL OPENINGS
3.1 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 3.5 below. The openings shown in Figs. E20
through E20.12 are approved. Other designs may be submitted for approval.
3.2 Calculations
Reinforcement for tank openings must be calculated by the following method:
• Area available within the rectangle abcd (see Figs. E20 through E20.12)
• 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)
0.90 when opening is in solid plate or flued-type reinforcement
e =
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)
C-III [M-1002] 216 10/2007

M-1002 APPENDIX E
3.3 Reinforcement Zone

3.3.1 The boundary of reinforcement zone must be determined as follows: The length ac or bd
(see Figs. E20 through E20.12) 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. E20.2
and E20.6), 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. E20.4, only 2 1/2 M must be used to determine the dimension above and below the tank shell.
3.3.2 The required reinforcement area must be provided in all planes passing through the center
of the opening and normal to the tank surface.
3.3.3 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.
3.3.4 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.
3.3.5 No metal added as corrosion allowance may be considered as reinforcement.
3.4 Dome Reinforcement
3.4.1 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:
3.4.1.1 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 3.3.1
above when calculating the tank shell reinforcement.
3.4.1.2 The total thickness of the dome, within the boundaries defined in paragraph 3.4.1.1
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. E20.9 or Fig. E20.10.
3.4.1.3 The dome shell thickness within the boundaries defined in paragraph 3.4.1.1 above must
consist of not more than two plates of the same material.
3.5 Openings in Knuckle Area
3.5.1 Any portion of an opening extending beyond the center 80% of the head diameter is consid-
ered to fall within the knuckle area.
3.5.2 All requirements of paragraph 3.2 above must be met.
3.5.3 Diameters must be measured in the plane of the opening.
3.5.4 Not less than 50% of the required material must be on each side of the centerline of the
opening.
3.5.5 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.
10/2007 C-III [M-1002] 217

APPENDIX E M-1002
3.6 Nozzle Connections

Nozzle reinforcements must be attached by welds having strengths no less than given by the
parameter W in Fig. E16.
4.0 MANWAY COVERS
4.1 Design—Covers for Pressure Cars
4.1.1 The dimensions and tolerances for the standard 18-in. manway cover are shown in Figs.
Fig. E5 and Fig. E6. The dimensions and tolerances for the standard 20-in. manway cover are
shown in Figures Fig. E7 and Fig. E8. Modified designs may be submitted for approval.
4.1.2 For larger diameter manways, the diametral dimensions must be increased commensu-
rately.
4.1.3 The minimum thickness of a manway cover must conform to DOT 179.101-1(a).
4.1.4 If the thickness calculated by the following formula exceeds that listed in DOT
179.101-1(a), the calculated thickness is the required minimum.

0.3p 1.78Whg 0.0003p 1.78Whg
t = d ----------- + ----------------------- t = d -------------------- + -----------------------
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 A3 or A4, psi Appendix A, Table A3 or A4, 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
2 2
W = 0.3927d p + 0.7854dmp + 152,500 lb W = 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.
4.1.5 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.
4.1.6 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 accommo-
date 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. E29 and E30 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
C-III [M-1002] 218 10/2007

M-1002 APPENDIX E
4.2 Openings in Pressure Car Manway Covers

4.2.1 Manway covers may be equipped with openings as illustrated in Figs. E19 through E19.23,
inclusive, or other approved openings.
4.2.2 Openings less than 2 3/8-in. (60.3-mm) diameter need not be reinforced.
4.2.3 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 thick-
ness must be calculated by either of the following methods:
4.2.3.1 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 4.2.4
below.
4.2.3.2 Calculate as provided in paragraph 4.1.4 above, except that the quantity under the
square root sign in the equation must be doubled.
4.2.4 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.
4.3 Design—Covers for Nonpressure Cars
4.3.1 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 4.3.3 below. Openings in cover must be reinforced in accord with ASME Code Part
UG-39.
4.3.2 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 4.3.3 below. Openings in cover must be reinforced in accord with ASME Code Part UG-
37.
4.3.3 The following additions or exceptions to ASME Code must be used when calculating covers
in accord with paragraphs 4.3.1 and 4.3.2 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
4.3.4 As an alternate to the requirements of paragraph 4.3.1 or 4.3.2 above, the cover may be
proven by testing as follows:
4.3.4.1 The closure must hold 1.25 times the prescribed tank test pressure for a minimum of
10 minutes without leakage or evidence of stress.
4.3.4.2 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.
4.3.4.3 Stresses in the closure must not exceed the material’s specified minimum yield strength,
as shown in the appropriate ASTM or AAR specification.
10/2007 C-III [M-1002] 219

APPENDIX E M-1002
4.3.5 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 4.3.5.3 below
and designated as standard manway style AAR-1 (see appropriate manway style chart in Appen-
dix D, Tables D7 through D12). Typical machined grooves are illustrated in Fig. E26. Other groove
configurations or retention methods are acceptable provided that the following criteria are met:
4.3.5.1 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. E26, item C.
4.3.5.2 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. E26, items A and B.
4.3.5.3 Any gasket configuration that produces an effective seal and provides adequate retention
may be applied at the manway; however, 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.
4.3.5.4 Modified designs that are not in accord with the above criteria must be submitted for
approval.
4.3.6 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.
4.3.6.1 Gasket sealing surfaces are to be machined to obtain a surface finish in the range of
63 microinches to 500 microinches, RMS.
4.3.6.2 Gasket sealing surface may be machined with concentric or spiral grooves. Grooving tool
should have a radius cutting surface.
4.3.7 For a new manway design or for a design not shown in the manway style charts in Appendix
D, Tables D7 through D12, design information and appropriate drawings are to be submitted to
AAR for inclusion in M-1002.
4.3.8 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.
4.4 Openings in Protective Housing Cover
When a weather cover designed for vertical discharge is required to cover an opening in a protec-
tive housing cover, the weather cover must be of the self-closing type. See Fig. E15 for typical
design.
4.5 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. E17.
Sealing compounds may be used to retain stud orientation.
C-III [M-1002] 220 10/2007

M-1002 APPENDIX E
5.0 PRESSURE RELIEF DEVICE CONNECTIONS FOR NONPRESSURE CARS

5.1 Standard Connections
Standard pressure relief device connections are shown in Fig. E21. Modified designs may be sub-
mitted for approval.
6.0 JOINT DESIGN
6.1 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 con-
nection with the minimum tensile strengths in Appendix M, is as follows:
Table E3. 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
plug welds (see Fig. E4, item B) or End Weld 52c/
single-welded butt with backup (see Fig. E4, item D) Side Weld 39
Double full fillet End Weld 52
Single-welded butt Shear 36
with backup (see) Tension and
Fig. E4, items C and D) Compression 81
a/ See Figs. E3 and E4.
b/ Values shown must be used, except when specified otherwise in the individ-
ual tank car specifications.
c/ If fillet weld is less than a full fillet, joint efficiency must be 35%. See Fig.
E4, item C.
6.2 Plug Welds

6.2.1 Plug welds must be used only in conjunction with fillet welds.
6.2.2 The shear value of each plug weld must be computed by the following formula:

1 2 2
L = 0.63 ⎛ D – --- ⎞ S 0.63 ( D – 6.35 ) S
L = -------------------------------------------
⎝ 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)
6.2.3 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.
6.2.4 See paragraph 7.1 below for plug welds on interior compartment heads.
10/2007 C-III [M-1002] 221

APPENDIX E M-1002
6.3 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.
6.4 Abutting Edges
6.4.1 A tapered transition section having a length not less than three times the offset between
the adjacent plate surfaces, as shown in Fig. E2, 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. E2.
6.4.2 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 max-
imum permissible offset of 1/8 in. (3.18 mm). This rule applies to all butt-welded joints in tank and
dome head.
6.4.3 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 thickness—25% of plate thickness
• For plates over 3/4 in. to 1 1/2 in. (19.0 mm to 38.1 mm) in thickness—3/16 in. (4.76 mm)
6.5 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 longi-
tudinal direction across each transition joint must not be greater than the following:
90
θ = -------
d for nonpressure tanks
---
t
175
θ = ---------
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)
θ = slope change across transition joint in degrees
C-III [M-1002] 222 10/2007

M-1002 APPENDIX E
7.0 COMPARTMENT HEADS

7.1 Inserted Heads
7.1.1 Inserted heads must be secured by means of the following:
• A single full fillet weld in combination with plug welds (see Fig. E4, item B)
• A single welded butt joint with backup in combination with a fillet weld (see Fig. E4, items
C and D)
7.1.2 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 E4. 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
7.1.3 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. E4, item D. When used in combi-
nation 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. E4, item C. Welds other than full fillet must have
minimum leg dimensions of 3/16 in. (4.76 mm).
7.2 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. E4, item A.
10/2007 C-III [M-1002] 223

APPENDIX E M-1002
8.0 VERTICAL CURVE CLEARANCE REQUIREMENTS

8.1 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
W 1.5 ( L – 4z ) W 0.125 ( L – 4z )
y = 0.75 ( S ) – ----- + V + --------------------------------- y = 0.75 ( S ) – ----- + V + ---------------------------------------
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)
8.2 y must not be less than 12 in. (305 mm) for outlets and washouts.
8.3 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
8.4 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.
C-III [M-1002] 224 10/2007

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

AND 120A TANK CAR TANKS
9.1 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 fol-
lowing 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 9.2.1, 9.2.2, and 9.2.3
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.
9.2 For bottom discontinuities not excluded above, a protective device must be designed as fol-
lows:
9.2.1 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.
9.2.2 The above load must be considered as concentrated on any transverse line on the protective
device.
9.2.3 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.
9.2.4 The longitudinal slope of the protective device must not exceed a ratio of 1:3.
9.2.5 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 above, the skid should
extend down to the extremity of the sump or discontinuity.
9.2.6 The skid, when used, must be of fabricated, cast, or forged design and be of material com-
patible with that to which it is attached.
9.2.7 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.
10/2007 C-III [M-1002] 225

APPENDIX E M-1002
9.2.8 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.
9.2.9 Bottom profile of the protective device must provide a sliding surface without discontinui-
ties.
10.0 PROTECTION OF BOTTOM AND TOP DISCONTINUITIES ON NONPRESSURE
TANK CAR TANKS
10.1 Bottom Protection
10.1.1 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 pro-
vided 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 10.1.2.1, 10.1.2.2,
and 10.1.2.3 below, without rupturing the tank.
10.1.2 For bottom discontinuities not excluded above, a protective device must be designed as fol-
lows:
10.1.2.1 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.
10.1.2.2 The above load must be considered as concentrated on any transverse line on the protec-
tive device.
10.1.2.3 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.
10.1.2.4 The longitudinal slope of the protective device must not exceed a ratio of 1:3.
10.1.2.5 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 10.1.1 above, the skid
should extend down to the extremity of the sump or discontinuity.
10.1.2.6 The skid, when used, must be of fabricated, cast, or forged design and be of material
compatible with that to which it is attached.
10.1.2.7 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.
C-III [M-1002] 226 10/2007

M-1002 APPENDIX E
10.1.2.8 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 sur-
face of the skid.
10.1.2.9 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.
10.1.2.10 Bottom profile of the protective device must provide a sliding surface without disconti-
nuities.
10.1.3 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 essen-
tially flat cover plates.
10.1.4 Class 207W pressure differential covered hopper cars are excluded from the requirements
of this section.
10.1.5 Levels of protection, as specified per 49 CFR 173.31(b)(5), are defined as follows:
10.1.5.1 Level A requires meeting the requirements of paragraphs 10.1.1, 10.1.2, and 10.1.3
above.
10.1.5.2 Level B requires that fittings exceeding the dimensions listed below be protected with a
protective device constructed to the requirements of paragraph 10.1.2 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.
10.1.5.3 Level C requires that fittings exceeding the dimensions listed below be protected with a
protective device constructed to the requirements of paragraph 10.1.2 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 follow-
ing 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).
10.2 Top Protection
10.2.1 When top fittings discontinuity protection is specified for nonpressure cars, the following
requirements must be met:
10.2.1.1 Protective devices must withstand design loads of 2W vertical and 1W horizontal
(applied in any horizontal direction), with each load applied separately as a uniform load over the
projected plane of the protective device. For the horizontal load, the height of the projected plane is
from the top of the tank at the longitudinal centerline to the top of the protective device. For pro-
tective housings, the cover is excluded from the projected height. The 1W design load is defined as
the car’s gross weight on rails less weight of trucks.
10.2.1.2 The allowable design stress for tank, nozzle, and protective device is the minimum ten-
sile strength of the material, provided that critical buckling stresses are not exceeded.
10/2007 C-III [M-1002] 227

APPENDIX E M-1002
10.2.1.3 Top fittings may be grouped and applied inside a protective housing (pressure car type)
or mounted on nozzles or flanges with roll-over (skid) protection. In either case, the protective
device must be designed to withstand the design loads without exceeding the specified allowable
stresses. For skid devices, attachments of skids to tank must be through pads, and the strength of
the skid attachment to pad must not exceed 70% of the strength of the pad attachment to tank.
10.2.1.4 Flush-mounted nozzles with blind flanges, caps, or plugs and external valves equipped
with internal check valves must be protected if their height profile, above the top of tank at the
longitudinal centerline, exceeds 5 in. for noninsulated cars or 6 in. for insulated cars.
10.2.1.5 Discontinuity protection is required for pressure relief valves and safety vents.
10.2.1.6 Discontinuity protection is not required for manway nozzles that are equipped with
manway covers that have internal or external shear rings designed to resist the horizontal loads in
roll-overs.
11.0 NONCIRCULAR NOZZLES
When noncircular nozzles are applied to a nonpressure tank car tank, the following conditions
must be met:
11.1 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 11.5 below.
11.2 If the long dimension is not parallel to the circumference of the shell, the design adequacy
must be verified, as provided in paragraph 11.5 below.
11.3 The nozzle must be designed to sustain bending stresses as determined by the following
steps:
11.3.1 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 σf in the center of the flat portion. See Table E5 and the following formula:

b 2 b 2
σ f = cp ⎛⎝ --- ⎞⎠ cp ⎛ --- ⎞
t ⎝t ⎠
σ f = --------------------
1000
where
σf = bending stress in the center of the flat portion of the nozzle

p = tank test pressure, psi (kPa)
c = proportionality factor (see Table E5)
11.3.2 Calculate the bending stress σc in the center of the curved portion by multiplying the
bending stress in the flat portion by the factor determined from Table E6.
σ c = qσ f
where
σc = bending stress in the center of the curved portion of the nozzle

q = proportionality factor (see Table E6)
C-III [M-1002] 228 10/2007

M-1002 APPENDIX E
11.3.3 The computed stress must not exceed one third of the minimum tensile strength of the
nozzle material.
11.4 Only the nozzle thickness in excess of that required for the bending load can be considered
as available as reinforcement.
11.5 As an alternative, or when the provisions of paragraphs 11.1 and 11.2 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. E22. When the tank is pressurized to its hydrostatic test pressure, the
measured stresses must not exceed the following:
Rosette
σu σu where
#1 σ ≤ ------ #4 σ ≤ ------
3 3
σ = maximum principal stress, psi (MPa)
σu σu σu = minimum tensile strength of the material, psi (MPa)
#2 σ ≤ ------ #5 σ ≤ ------
3 3 τ = maximum shear stress, psi (MPa)
σu
#3 τ ≤ ------
4
Table E5. Proportionality factors for σf

Aspect ratio αa/ 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, α = a/b and c = c1
If b < a, α = b/a and c = c2
Table E6. Proportionality factors for σc

b/d q
a
0 0.571
0.1 0.624
0.2 0.674
b 0.3 0.720
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
10/2007 C-III [M-1002] 229

APPENDIX E M-1002
12.0 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:
12.1 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

Mc 10 Mc
6
S b = -------- S b = -----------------
I 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)
12.2 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 mini-
mum tensile strength of the tank shell material as given in Appendix M, calculated by the follow-
ing formula:

H 500H
S c = aS b + ------- S c = aS b + -------------
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 (see Chapter 6, paragraph 6.1.9),
ft (mm)
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)
12.3 Anchor designs must be verified by calculations or test to ensure that the tank will not expe-
rience permanent deformation at the ends of the anchor under the imposition of impact loads as
specified in Chapter 6, paragraph 6.2.4).
12.4 In lieu of designing to paragraphs 12.1 and 12.2 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:
12.4.1 The thickness of the reinforcing plate must be not less than 0.5 in. (12.7 mm).
C-III [M-1002] 230 10/2007
M-1002 APPENDIX E
12.4.2 The reinforcing plate must extend transversely, beyond each leg of the anchor, for a mini-
mum distance of the outside radius of the tank divided by 10.
12.4.3 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 = --- π 4 ----------------------
-
2
3 3(1 – μ )
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)
μ = Poisson’s ratio
12.4.4 The reinforcing plates must have corner radii not less than 2 1/2 in. (63.5 mm).
12.4.5 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.
12.4.6 Plate elements of an anchor section that conform to paragraphs 12.4.1 and 12.4.2 above,
and whose length, L, beyond the extreme ends of the anchor leg, conforms to paragraph 12.4.3
above, may be considered to be reinforcement plates.
13.0 HEAD-TO-SILL ATTACHMENTS
New stub sill tank cars that are equipped with head braces must be designed such that the out-
board 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 Chap-
ter 6.
14.0 BOTTOM OUTLET VALVE AND NOZZLE ARRANGEMENTS
14.1 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).
14.2 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:
14.2.1 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 pub-
lished tensile strength for the nozzle material (for a vee groove) or for the nozzle bolting material,
10/2007 C-III [M-1002] 231

APPENDIX E M-1002
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.
14.2.2 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.
15.0 REINFORCING PADS
15.1 Requirements for Use of Reinforcing Pads
15.1.1 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 attach-
ments, 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 acci-
dent.
15.1.2 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
15.1.3 Tank attachments shall be designed to collapse or shear off, without loss of lading, in the
event of an accident.
15.2 Design of Reinforcing Pads
When reinforcing pads are used under brackets attached to tank car tanks, the following criteria
shall be observed:
15.2.1 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.
15.2.2 Pads shall be attached by continuous fillet welds, except for venting provisions. The ulti-
mate 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 thick-
ness.
15.2.3 Pads shall have each corner rounded to a 1-in. minimum radius.
15.2.4 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.
16.0 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.
C-III [M-1002] 232 10/2007

M-1002 APPENDIX E
3
"
16 1
8 "
3
" OPENING
16
1
8 "
3
" OPENING
16
SECTION AA
¾" R
¼ ½"
IN
12
"M
10 12
½
10
"
¾
"
¼"
¼"
A
½" MAX 3
8 "R
A
2 16" MAX
1 ½" R
2 16" MIN
13
5
¾" R
2 8 " MAX
2 16" MIN
7
8 "R
2¼
"
2¼
"
5
"
1¾
½" MAX ¼" R

10
¼"
¼
"M
¾" R
"
¾
IN
10
METHOD OF ATTACHMENT
OPTIONAL
PLACARD OUTLINE
Fig. E1 Limiting dimensions for metal placard holder
10/2007 C-III [M-1002] 233

APPENDIX E M-1002
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. E1.1 Limiting dimensions for metal placard holder—SI units
C-III [M-1002] 234 10/2007

M-1002 APPENDIX E
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. E2 Butt welding of plates of unequal thickness
10/2007 C-III [M-1002] 235

APPENDIX E M-1002
PLANE IN SHEAR
END WELD
IN SHEAR
PLANE
SIDE WELD
SINGLE
Fig. E3 Fillet welds
C-III [M-1002] 236 10/2007

M-1002 APPENDIX E
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 ½" 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
½" 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. E4 Acceptable joints for interior heads of compartment tank cars
10/2007 C-III [M-1002] 237

APPENDIX E M-1002
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. E4.1 Acceptable joints for interior heads of compartment tank cars—SI units
C-III [M-1002] 238 10/2007

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 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
73 20 STUDS (BOLTS OPTIONAL FOR

/8''
/4' GASES OTHER THAN CHLORINE)

71
'R
AD EQUALLY SPACED
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. E5 Standard manway cover for 18-in. manway (see details in Fig. E19 series)
10/2007 C-III [M-1002] 239

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 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. E5.1 Standard manway cover for 18-in. manway (see details in Fig. E19 series)—SI units
C-III [M-1002] 240 10/2007

M-1002 APPENDIX E
33'' DIA.
31'' DIA.
25 ½" DIA.
DRILL 1 16" DIA. HOLES FOR 1 8 " DIA. STUDS

5 1
1
8 "
2¼" MIN.
1 ¾"
3
8 " ¼"R ¼"
17¼" DIA. DRILL AND TAP THROUGH
3/4'' 10 UNC 2B
19.238'' ± .010'' DIA.
19 ½" 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
19¾" 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. E6 Detail of cover and nozzle joint for 18-in. manway
10/2007 C-III [M-1002] 241

APPENDIX E M-1002
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. E6.1 Detail of cover and nozzle joint for 18-in. manway—SI units
C-III [M-1002] 242 10/2007

M-1002 APPENDIX E
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. E7 Standard manway cover for 20-in. manway (see details of openings in Fig. E19 series)
10/2007 C-III [M-1002] 243

APPENDIX E M-1002
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. E7.1 Standard manway cover for 20-in. manway (see details of openings in Fig. E19 series)—SI units
C-III [M-1002] 244 10/2007

M-1002 APPENDIX E
35'' DIA.
33'' DIA.
27 ½" DIA.
DRILL 1
5
" DIA. HOLES FOR 1
16
1
8 " DIA. STUDS
1
8 "
2 ¼" MIN.
1 ¾"
3
8 " ¼" R ¼"
19 ¼" DIA. DRILL AND TAP THROUGH
3/4'' 10 UNC 2B
21.238'' ± .010'' DIA.
21 ½" 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 ¾" 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. E8 Detail of cover and nozzle joint for 20-in. manway
10/2007 C-III [M-1002] 245

APPENDIX E M-1002
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. E8.1 Detail of cover and nozzle joint for 20-in. manway—SI units
C-III [M-1002] 246 10/2007

M-1002 APPENDIX E
29
" DIA. THROUGH
32
29
" DIA. THROUGH
32
TAP ¾" NPT TAP ¾" 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. E19.8 FOR DETAILS
ON 29" DIA. BOLT CIRCLE (3 PLACES)
LOCATED AS SHOWN
(6 PLACES)
F
E
E
F
36°
36°
R8
45°
½
¼
R7
45° 45°
LONGITUDINAL AXIS
½ OF TANK CAR
¾
R6
36°
36°
45°
33" DIA.
GAUGING DEVICE INTERFACE 31" DIA. BC
SEE Fig. E19.25 FOR DETAILS
TWENTY 1 5 16" DIA. HOLES
EQUALLY SPACED
COVER TO NOZZLE JOINT ON 25" DIA. BC
SEE Fig. E10 FOR DETAILS
SAFETY VALVE INTERFACE
TWENTY HOLES DRILLED AND
TAPPED FOR ¾"10 STUDS
EQUALLY SPACED ON 31" DIA. BC
Fig. E9 Standard manway cover for 20-in. manway—VCM (see details of openings in Fig. E19 series)
10/2007 C-III [M-1002] 247

APPENDIX E M-1002
33" DIA.
31" DIA. BC
1
8 " 27" DIA.
25" DIA. BC
1 ¾" 2 ¼" MIN.
¼" 19 ¼" DIA.

DRILL AND TAP FOR 3
" R ¼"
¾"10 UNC2B THROUGH
8 21.238" ± .010 DIA.
EQUALLY SPACED 21 ½" 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 ¾" 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. E10 Detail for cover and nozzle joint for 20-in. manway—VCM
C-III [M-1002] 248 10/2007

M-1002 APPENDIX E
29
" DIA. THROUGH
32
29
" DIA. THROUGH
32
TAP ¾" NPT TAP ¾" NPT
VARIOUS DEVICES BY VARIOUS DEVICES BY

MANUFACTURERS MANUFACTURERS
(OPTIONAL) (OPTIONAL)
SAMPLE OPENING THERMOWELL OPENING
SECTION EE SECTION FF
29" DIA.
27" DIA. ANGLE VALVE INTERFACE
DRAIN HOLES 1" DIA. THROUGH SEE Fig. E19.8 FOR DETAILS
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
½
45° 45°
LONGITUDINAL AXIS
OF TANK CAR
5 8 "
R7
36°
36°
45°
35" DIA.
GAUGING DEVICE INTERFACE
SEE Fig. E19.25 FOR DETAILS 33" DIA. BC
TWENTY 1 16" DIA. HOLES

5
EQUALLY SPACED
COVER TO NOZZLE JOINT ON 27" DIA. BC
SEE Fig. E12 FOR DETAILS
SAFETY VALVE INTERFACE
TWENTY HOLES DRILLED AND
TAPPED FOR ¾"10 STUDS EQUALLY
SPACED ON 33" DIA. BC
Fig. E11 Standard manway cover for 22-in. manway—VCM (see details of openings in Fig. E19 series)
10/2007 C-III [M-1002] 249

APPENDIX E M-1002
35" DIA.
33" DIA. BC
1
8 " 29" DIA.
27" DIA. BC
1 ¾" 2 ¼" MIN.
¼" 21 ¼" DIA.

DRILL AND TAP FOR 3
8 " R ¼" 23.238" ± .010 DIA.
¾"10 UNC2B THROUGH
EQUALLY SPACED 23 ½" 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 ¾" 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. E12 Detail for cover and nozzle joint for 22-in. manway—VCM
C-III [M-1002] 250 10/2007

M-1002 APPENDIX E
0.75"
34.00" +.00
-.25 FOR 20" MANWAY
+.00
36.00" -.25 FOR 22" MANWAY
13.50" ±.75
4.00" ± .25
Ø5.00" ± .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. E13 Protective housing for 20-in. and 22-in. VCM tank car cover plates
10/2007 C-III [M-1002] 251

APPENDIX E M-1002
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. E14 Shell-full for typical tank car types
C-III [M-1002] 252 10/2007

M-1002 APPENDIX E
TYPICAL WEATHER COVER

(SELF-CLOSING)
PROTECTIVE HOUSING COVER
MINIMUM OPENING
OPTIONAL EXHAUST FLUE
DISCHARGE CHANNEL
PRESSURE RELIEF VALVE
Fig. E15 Detail for opening in protective housing cover for transporting liquefied flammable gases
10/2007 C-III [M-1002] 253

APPENDIX E M-1002
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) × 10-3
B Nozzle wall shear = 1.57 BTn (.70Sn) = 1.57 BTn (.70Sn) × 10-3
C Groove weld tension = 1.57 AH (.74Sp) = 1.57 AH (.74Sp) × 10-3
D Outer fillet weld in shear = 1.57 CG (.49 Sp) = 1.57 CG (.49 Sp) × 10-3
E Groove weld tension = 1.57 AJ (.74 Sp) = 1.57 AJ (.74 Sp) × 10-3
Explore possible paths of failure using W = (2t – M) DS in conventional units or

W = (2t – M) DS × 10-3 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. E16 Nozzle attachment welds
C-III [M-1002] 254 10/2007

M-1002 APPENDIX E
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
¼" DIA. CABLE SEAL LOCK
TYPICAL
2 8"
5
HVY
HEX
COVER PLATE
7
8 "
3
8 " DIA. HOLE
1 ¼"
TOP OF STANDARD
LENGTH STUD
Fig. E17 Tank car safety seal for pressure cars
10/2007 C-III [M-1002] 255

APPENDIX E M-1002
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 ¾" 4 ¼" REF 1 8"

1
2 ¼" REF
" 5 ½"
5 1
" OPTIONAL 125
4 8 " REF
8 16
¼"
1'' REF 3.00'' CORE REF 5
" REF
1
8
¼" 60°
2.00'' CORE
1 8 " REF
3
45° 1 ¼" REF
125 45° REF
¼" SEE NOTE 1
MINOR DIA. 4.920''MAXIMUM
3 8 " REF
7
1 ¾" (MIN. NOT SPEC.)
PITCH DIA. 5.052'' 5.064'' 4'' REF
MAJOR DIA. 5.203'' 5.226'' 6 ¼" REF
NOZZLE E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE ½" 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 manufacturer’s 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. E18.7 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. E18.6 to the 1 5/8-in. depth), the nozzle must be removed from service.
Fig. E18 4-in. bottom outlet cap and nozzle thread standard
C-III [M-1002] 256 10/2007
M-1002 APPENDIX E
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. E18.7 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. E18.6 to the 1 5/8-in. depth), the nozzle must be removed from service.
Fig. E18.1 4-in. bottom outlet cap and nozzle thread standard—SI units
10/2007 C-III [M-1002] 257
APPENDIX E M-1002
9 ½" REF
8 ½" 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 ½" 8 "

5
LOCKING SET SCREWS
5
8 "
2 8 " REF
1 8 " REF
1
4 ¾" REF
½" REF 8'' 125 1''
7
8 " REF
5 1
" OPTIONAL
16
8 " REF 3 5 8 " CORE

5
OPTIONAL
REF
½" 1 ¼" REF ½" HOLE FOR
CAR SEAL
¼" 60° 2'' CORE (OPTIONAL)
1 ¾"
45° 45° REF

125
SEE NOTE 1
¼"
MINOR DIA. (MIN. NOT SPEC.) 4 ½" 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
OUTLET CAP
Notes:
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.
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. E18.8 to the 1 1/2-in. depth), the nozzle must be removed from service.
Fig. E18.2 6-in. bottom outlet cap and nozzle thread standard
C-III [M-1002] 258 10/2007
M-1002 APPENDIX E
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
OUTLET CAP
Notes:
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 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.
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. E18.8 to the 1 1/2-in. depth), the nozzle must be removed from service.
Fig. E18.3 6-in. bottom outlet cap and nozzle thread standard—SI units
10/2007 C-III [M-1002] 259
APPENDIX E M-1002
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 ¼"4 UN ANSI B1.1 5 ¼"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 ¼"4 SPECIAL 2A 5 ¼"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 ¼" 4 SPECIAL 2A NOZZLE THREAD DIAMETERS ARE
0.020" LESS THAN THE 5 ¼" 4 UN 2A OF ANSI B1.1 STANDARD.
2. MAXIMUM MINOR DIAMETER FOR HOSE COUPLINGS IS 4.984"
INSTEAD OF 5.017".
Fig. E18.4 5 1/4-in.–4 thread layout
C-III [M-1002] 260 10/2007

M-1002 APPENDIX E
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. E18.5 8-in.–4 thread layout
10/2007 C-III [M-1002] 261

APPENDIX E M-1002
7 8"
1
5.141"
(2) 1 8 " × 45°
1.750"
Ø 7 16" (OPTIONAL)
2 ¾"
¾"
NO-GO GAUGE FOR
AAR 5 ¼"4 THREAD NOZZLE
½" (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. E18.7 IN A SINGLE GAUGE CONFIGURATION.
Fig. E18.6 Gauge for worn threads—4-in. bottom outlet nozzle
6"
(4) 32" × 45°
1
1" Ø 7 16" (OPTIONAL)
½"
1 8"
3 NO-GO GAUGE FOR
AAR 5 ¼"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
THE GAUGE MANUFACTURER, PROVIDED THAT THE FUNCTION OF THE GAUGE IS
NOT IMPAIRED.
Fig. E18.7 Gauge for worn threads—4-in. bottom outlet cap or coupling
C-III [M-1002] 262 10/2007
M-1002 APPENDIX E
10 ¼"
7.890"
(2) 8 " × 45°
1
Ø 16" (OPTIONAL)
7
1.625"
2 ¾"
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.
5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO SUIT
paragraph 3.6) THE GAUGE MANUFACTURER, PROVIDED THAT THE FUNCTION OF THE GAUGE IS
NOT IMPAIRED.
Fig. E18.8 Gauge for worn threads—6-in. bottom outlet nozzle
8 8"
3
13
"
16 Ø 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 ½" DIA. (REF)
X = 1 ½" 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. E18.9 Gauge for worn threads—6-in. bottom outlet cap or coupling
10/2007 C-III [M-1002] 263

APPENDIX E M-1002
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. E18.10 Detail for mounting condition of bottom outlet valves
C-III [M-1002] 264 10/2007

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

IN VALVE FLANGE
¼"
1.505'' ± .003' DIA.

1 ¾" DIA.
2'' DIA. 1
" DIA. GROOVES
16
2.245'' ± .003'' DIA.
3 ½" DIA. B.C. DRILL AND TAP FOR FOUR

¾'' 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 ¼" NPT

Fig. E19 Detail of mounting conditions for 1-in. angle valve
10/2007 C-III [M-1002] 265

APPENDIX E M-1002

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

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 ¼" NPT

Fig. E19.1 Detail of mounting conditions for 1-in. angle valve—SI units
C-III [M-1002] 266 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
3.255'' ± .003'' DIA.
3 ½" DIA.
3 ¾" DIA.
1
"
16 DIA. GROOVES
3.995'' ± .003'' DIA.
DRILL AND TAP FOR FOUR

6 ¼" DIA. B.C. ¾'' 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 ¼"
"
8
7
DRILL AND TAP 2'' NPT OR 2 ½" NPT
Fig. E19.2 Detail of mounting conditions for 2-in. angle valve for tank with 2-in. eduction pipes
10/2007 C-III [M-1002] 267

APPENDIX E M-1002

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. ¾'' 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 ½" NPT
Fig. E19.3 Detail of mounting conditions for 2-in. angle valve for tank with 2-in. eduction pipes—SI units
C-III [M-1002] 268 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
3.255'' ± .003'' DIA.
3 ½" DIA.
1
" DIA. GROOVES
16
3 ¾" 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 ¼"
8
16
7
1 18 "
EXCESS FLOW VALVE

2
5
8 " DIA. WELDED TO COVER
2.906'' DIA.
Fig. E19.4 Detail of mounting conditions for 2-in. angle valve for tanks with 2-in. eduction pipes
10/2007 C-III [M-1002] 269

APPENDIX E M-1002

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

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. E19.5 Detail of mounting conditions for 2-in. angle valve for tanks with 2-in. eduction pipes—SI units
C-III [M-1002] 270 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
3.255'' ± .003'' DIA.

3 ½" DIA.
3 ¾" DIA. 1
"
16 DIA. GROOVES
3.995'' ± .003'' DIA.
6 ¼"DIA. B.C. DRILL AND TAP FOR FOUR

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 ¼"
7
7
" MIN.
16
DRILL AND TAP 3'' NPT OR 3 ½'' NPT

Fig. E19.6 Detail of mounting conditions for 2-in. or 3-in. angle valve for tanks with 3-in. eduction pipes
10/2007 C-III [M-1002] 271

APPENDIX E M-1002

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

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 ½'' NPT

Fig. E19.7 Detail of mounting conditions for 2-in. or 3-in. angle valve for tanks with 3-in. eduction pipes—SI units
C-III [M-1002] 272 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
3.255'' ± .003'' DIA.
3 ½" DIA.
3 ¾" 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 ¼"
¾"
EXCESS FLOW VALVE

3.505'' DIA. WELDED TO COVER
Fig. E19.8 Detail of mounting conditions for 2-in. or 3-in. angle valve for tanks with 3-in. eduction pipes
10/2007 C-III [M-1002] 273

APPENDIX E M-1002

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

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. E19.9 Detail of mounting conditions for 2-in. or 3-in. angle valve for tanks with 3-in. eduction pipes—SI units
C-III [M-1002] 274 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
1.505'' ± .003'' DIA.
1 ¾" DIA.
2'' DIA. 1
" DIA. GROOVES
16
2.245'' ± .003'' DIA.

4
1
8 " DIA. B.C. ¾'' 10 UNC 2A STUDS
2.255'' ± .003'' DIA.
1
7
8 " DIA. 1
16 " DIA. GROOVE
1.495'' ± .003'' DIA. 1

8 " GASKET
3
"
16
1 ¼" DIA.
"
8
1 ¼"
DRILL AND TAP 1 ¼'' NPT

Fig. E19.10 Detail of mounting conditions for gauging device
10/2007 C-III [M-1002] 275

APPENDIX E M-1002

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

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 ¼'' NPT

Fig. E19.11 Detail of mounting conditions for gauging device—SI units
C-III [M-1002] 276 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
1.505'' ± .003'' DIA.
1 ¾" DIA. B.C.
2'' DIA. 1
16 " DIA. GROOVES
2.245'' ± .003'' DIA.
4 8 " DIA. B.C.

1 DRILL AND TAP FOR FOUR
2.255'' ± .003'' DIA.
1 8 " DIA. " DIA. GROOVE

7 1
16
1.495'' ± .003'' DIA.

1
8 " GASKET
3
"
16
1 ¼" DIA.
1 ¼"
"
7
8
¾"
1.531'' DIA.
Fig. E19.12 Detail of mounting conditions for gauging device
10/2007 C-III [M-1002] 277

APPENDIX E M-1002

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

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. E19.13 Detail of mounting conditions for gauging device—SI units
C-III [M-1002] 278 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
1.505'' ± .003'' DIA.

1 ¾" DIA.
2'' DIA. 1
" DIA. GROOVES
16
2.245'' ± .003'' DIA.

6 ¼" DIA. B.C. DRILL AND TAP FOR FOUR
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 ¼"
8
7
3
8 "R
1 ¾" DIA.
Fig. E19.14 Detail of mounting conditions for pressure relief valve
10/2007 C-III [M-1002] 279

APPENDIX E M-1002

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

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. E19.15 Detail of mounting conditions for pressure relief valve—SI units
C-III [M-1002] 280 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
4.005 ± .003'' DIA.
4 ¼" DIA.
4 ½" DIA. 1
" DIA. GROOVES
16
4.745'' ± .003'' DIA.
6 ¼" DIA. B.C. DRILL AND TAP FOR FOUR

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
½"
"
1 ¼"
3
"
8
8
7
3 8 " DIA.
3
10/2007 C-III [M-1002] 281

APPENDIX E M-1002

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.
C-III [M-1002] 282 10/2007

M-1002 APPENDIX E
DRILL 8 " DIA. HOLES

7
IN VALVE FLANGE
¼"
4.255 ± .003'' DIA.
4 ½" DIA.
4 ¾" DIA. 1
" DIA. GROOVES
16
4.995 ± .003'' DIA.
6 ½" DIA. B.C. DRILL AND TAP FOR FOUR

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
½"
"
1 ¼"
"
8
3
7
3 ¾"
10/2007 C-III [M-1002] 283

APPENDIX E M-1002

IN VALVE FLANGE
6.35
108.01 TO 108.15 DIA.

114 DIA.
126.80 TO 126.94 DIA.

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
C-III [M-1002] 284 10/2007

M-1002 APPENDIX E
DRILL 16" DIA. HOLES

15
IN VALVE FLANGE
¼"
6.005 ± .003'' DIA.

6 ¼" DIA.
6 ½" 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
10/2007 C-III [M-1002] 285

APPENDIX E M-1002
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
C-III [M-1002] 286 10/2007

M-1002 APPENDIX E

IN VALVE FLANGE
¼"
7.255'' ± .003'' DIA.
7 ½" DIA.
7 ¾" 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 ¼"
10/2007 C-III [M-1002] 287

APPENDIX E M-1002

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
C-III [M-1002] 288 10/2007

M-1002 APPENDIX E
DRILL ¾" DIA. HOLES

IN VALVE FLANGE
¼"
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"
¾"
1"
AS REQUIRED
Fig. E19.24 Detail of mounting condition for 3-in. full ported flanged ball valves for nonpressure tank cars using
ANSI B16.5 large tongue design
3 ¼" DIA. BC
2.255" ± .003" DIA.

17
" DIA. 1 1 8 " DEEP
32
1 8 " DIA.
7
TAP
5
8 " 11 UNC2B ¾" DEEP
EQUALLY SPACED 1.495 ± .003" DIA.
1
" DIA. GROOVE
16
(4 PLCS) 1
32" DEEP
3
"
16
1 ¼" DIA.
¾"
1.531" DIA.
Fig. E19.25 Gauging device interface VCM tank cars
10/2007 C-III [M-1002] 289

APPENDIX E M-1002
SMALLER OF
a c .7N OR .7M
2½N 2½M
M
D
2½M
b
d SMALLER OF
.7N OR .7M
D D
Fig. E20 Reinforced openings in tank shell—flued nozzle, lap welded
D N
a c SMALLER OF
2½N K .7N OR .7M
2½M
M
2½M
b ½N
d
D D
Fig. E20.1 Reinforced openings in tank shell—built-up nozzle with pad
D N
c
a
R 2½N 2½M
M
2½M
b
d
D D
Fig. E20.2 Reinforced openings in tank shell—flued nozzle, butt-welded

C-III [M-1002] 290 10/2007
M-1002 APPENDIX E
D N
SMALLER OF
¼" (6.35) OR .7N
a c
2½N K 2½M
M
2½M
b
d SMALLER OF
D D ½ M OR ½ K
Fig. E20.3 Reinforced openings in tank shell—built-up nozzle with reinforcement
D N
a c
2½M
K M
2½M SMALLER OF SMALLER OF

b ½ M OR ½ K .7N OR .7M
d
D D
Fig. E20.4 Reinforced openings in tank shell—dome shell outside reinforcement boundary
SMALLER OF
a c .7N OR .7M
R 2½N
2½M
D 2½M
SMALLER OF
b .7N OR .7M
d
D D
Fig. E20.5 Reinforced openings in tank shell—flued nozzle, tapered, lap-welded

10/2007 C-III [M-1002] 291
APPENDIX E M-1002
D N
a c
2½N 2½M
K M
2½M
b
d .7 K
D D
Fig. E20.6 Reinforced openings in tank shell—flued opening abutting tank shell
D N
SMALLER OF
c ¼" (6.35) OR .7N
a
2½M
OR
2½N M
2½M
b
d
D D
Fig. E20.7 Reinforced openings in tank shell—built-up nozzle, butt-welded
SMALLER OF
¼" (6.35) OR .7N
D N
a c
K 2½N
2½M
M
SMALLER OF
2½M
½ M OR ½ K
b
d SMALLER OF
.7M OR .7N = TW
D D
SMALLER OF
.7N OR .7K = TW
Fig. E20.8 Reinforced openings in tank shell—built-up nozzle with reinforcement
C-III [M-1002] 292 10/2007
M-1002 APPENDIX E
SMALLER OF
.7 N OR .7 L
IDD N SMALLER OF
¼" (6.35) OR .7N SMALLER OF
½ M OR ½ K
L
c
a 4" (102) ON
K 2½N 2½M
LONG CL
SMALLER OF
2½M 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. E20.9 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 ½ M OR ½ K
SMALLER OF
c ¼" (6.35) OR .7L
a 4" (102) ON
K 2½N 2½M
LONG CL
SMALLER OF
2½M 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. E20.10 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
2½M
2½N M
D 2½M
b
.7 M d
D D
Fig. E20.11 Flued reinforcement for dome opening 30 in. or less
10/2007 C-III [M-1002] 293
APPENDIX E M-1002
N
D
c
FULL a
PENETRATION 2 ½ M 2½N
WELD M
2½M 2½N
d
SMALLER OF b
¼" (6.35) OR .7N D D
Fig. E20.12 Built-up nozzle with full penetration weld
C-III [M-1002] 294 10/2007

M-1002 APPENDIX E
¾" DIA. EIGHT HOLES
¾" DIA. FOUR HOLES

10 ¼" BOLT CIRCLE 6'' SQ. MIN.
6 ¼" BOLT CIRCLE
12'' DIA.
7 ½" DIA. MIN.
7.1875'' ± .005'' DIA.
2 8 " DIA. MIN.
7
6 ½" ± " LINED OR UNLINED

1
32
LINED OR UNLINED
¼"
FLANGE MAY BE SQUARE OR ROUND

A B
THREE HOLES DIA. TO SUIT
7.652'' MAJOR DIA. EQUALLY SPACED
5 ½" BOLT CIRCLE
1 ½" MIN.
7'' DIA. MIN.

7'' TAPER PIPE THREAD
8 THREADS PER INCH 1 ¾" DIA. MIN.
2'' N.P.T. AFTER LINING
C
D FOR RUBBER LINED TANKS ONLY

E
Fig. E21 Pressure relief device connections for nonpressure cars
10/2007 C-III [M-1002] 295

APPENDIX E M-1002
¾" DIA. EIGHT HOLES
¾" 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. E21.1 Pressure relief device connections for nonpressure cars—SI units
C-III [M-1002] 296 10/2007

M-1002 APPENDIX E
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. E22 Strain gauge rosette location
10/2007 C-III [M-1002] 297

APPENDIX E M-1002
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. E23 Detail of nominal 2-in.-diameter rupture disc device
C-III [M-1002] 298 10/2007

M-1002 APPENDIX E
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. E23.1 Detail of nominal 2-in.-diameter rupture disc device—SI units
Fig. E24 <This caption must become white text; there is no Fig. E24, but there must be a holder for it.>
10/2007 C-III [M-1002] 299

APPENDIX E M-1002
2 3
4
6
4
Fig. E24.1 Bolted flange closure
1 Fig. E24.4 Quick-coupling device with external

threaded cap closure
1
7
4
6
Fig. E24.2 Threaded cap closure
4
1
Fig. E24.5 Quick-coupling device with internal threaded
cap closure
1
5
5
7
6
8
Fig. E24.3 Quick-coupling device with threaded plug
closure
4
Fig. E24.6 Quick-coupling device with auxiliary test

valve and internal threaded cap closure
Bottom outlet closure arrangements

C-III [M-1002] 300 10/2007
M-1002 APPENDIX E
1 1
4*
4
8
5
Fig. E24.7 Quick-coupling device with internal threaded

cap closure and alternative test valve
1
10
4*
* Either Location Acceptable
Fig. E24.9 Two-piece quick-coupling device with auxil-
iary 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. E24.8 Two-piece quick-coupling device with inte-
gral 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
10/2007 C-III [M-1002] 301

APPENDIX E M-1002
Fig. E25 <This caption must become white text; there is no Fig. E25, but there must be a holder for it.>
HIGHEST POINT ON COVER
15 ½"
OUTSIDE DIAMETER
TANK SHELL
Fig. E25.1 Top fittings profile nonpressure cars—hinged manway
DIMENSION
A
OUTSIDE DIAMETER
TANK SHELL
Valve Size 2 in. 3 in.

Dimension A 19 ¼" 22 ¾"
NOTE:
DIMENSION A IS APPLICABLE FOR EITHER
THREADED OR FLANGED VALVES AND PLUGS
Fig. E25.2 Top fittings profile nonpressure cars—multihousing (welded cover plate)
C-III [M-1002] 302 10/2007
M-1002 APPENDIX E
Dimension
A
OUTSIDE DIAMETER
TANK SHELL
Valve Size 2 in. 3 in.

Dimension A 20 ½" 24"
NOTE:
DIMENSION A IS APPLICABLE FOR EITHER
THREADED OR FLANGED VALVES AND PLUGS
Fig. E25.3 Top fittings profile nonpressure cars—multihousing (bolted cover plate)
20"
OUTSIDE DIAMETER
TANK SHELL
Fig. E25.4 Top fittings profile nonpressure cars—6-in. pressure relief valve
10/2007 C-III [M-1002] 303

APPENDIX E M-1002
22 ¼"
OUTSIDE DIAMETER
TANK SHELL
Fig. E25.5 Top fittings profile nonpressure cars—3-in. top style pressure relief valve
15 ¼"
OUTSIDE DIAMETER
TANK SHELL
Fig. E25.6 Top fittings profile nonpressure cars—3-in. pressure relief valve
C-III [M-1002] 304 10/2007
M-1002 APPENDIX E
15 ¾"
OUTSIDE DIAMETER
TANK SHELL
Fig. E25.7 Top fittings profile nonpressure cars—2-in. rupture disc device
THREADED FLANGED 28 ¼"
OUTSIDE DIAMETER
TANK SHELL
Fig. E25.8 Top fittings profile nonpressure cars—rupture disc device or vacuum relief valve applied on hinged man-
way cover
27 ½"
OUTSIDE DIAMETER
TANK SHELL
Fig. E25.9 Top fittings profile nonpressure cars—pressure relief valve applied on hinged manway cover
10/2007 C-III [M-1002] 305
APPENDIX E M-1002
25 ½"
OUTSIDE DIAMETER
TANK SHELL
NOTE:
NONINSULATED RUBBER-LINED CARS
Fig. E25.10 Top fittings profile nonpressure cars—manway with nozzle—hydrochloric acid car
34"
OUTSIDE DIAMETER
TANK SHELL
NOTE:
NONINSULATED RUBBER-LINED CARS
Fig. E25.11 Top fittings profile nonpressure cars—manway with nozzles and valve—hydrochloric acid car
C-III [M-1002] 306 10/2007

M-1002 APPENDIX E
26 ¾"
OUTSIDE DIAMETER
TANK SHELL
Fig. E25.12 Top fittings profile nonpressure cars—manway with nozzles—sulfuric 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 4.3.1 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. E26 Gasket grooves for AAR-1 manway style
10/2007 C-III [M-1002] 307
APPENDIX E M-1002
Ø*
QTY (*)
ON * B.C.
Ø* Ø* Ø* Ø* ØB
*
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. E19 through Fig. E19.25.
Fig. E27 Detail of pressure car blind flange for 1-in. angle valve or gauging device
6.00" (152 mm) * Dimensions to be per applicable Fig. E19 through Fig. E19.25.
Ø*
QTY (*)
ON * B.C.
Ø* Ø* Ø* Ø*
6.00" (152 mm)
*
R.81" (R21 mm) TYP
1" (25 mm)
Fig. E28 Detail of pressure car blind flange for 2-in. or 3-in. angle valve
C-III [M-1002] 308 10/2007
M-1002 APPENDIX E
8 ¼"
R1 16"
9
TRANSVERSE
CENTERLINE A A 11
"
D 8 16
SAMPLING VALVE ½"
6° TYP
THERMOMETER WELL
C
GAUGING DEVICE
ANGLE VALVE 9 ¼"

3 PLACES R1 ½"
B
PROTECTIVE LONGITUDINAL 9 ¼"
½"
HOUSING CENTERLINE
MOUNTING 6° TYP
(SEE NOTE)
A A
C
Ø6
DRAIN HOLES 8"
R1 8 "
3
3
8 "
LARGE SAFETY VALVE B
8" D
½"
Ø3
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. E29 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
1
6 8 " SQUARE
3
7
5
23
"
32
1 2
6BMV 24BMV
MOLDED VITON GASKET MOLDED VITON GASKET
2
PRESSURE RELIEF DEVICE
Fig. E30 Capping clearances for standard chlorine cars with 18-in. manways
10/2007 C-III [M-1002] 309
APPENDIX E M-1002
C-III [M-1002] 310 10/2007

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-III–312
3.0 Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
3.1 Stages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
4.0 Items Not Converted to SI Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
4.1 Specification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
4.2 Obsolete Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
4.3 Appendix M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
4.4 Appendix W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
4.5 Bolt and Pipe Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
4.6 Accepted Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–313
5.0 Stage 1 Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–314
5.1 Standard Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–314
5.2 Conversion Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–314
5.3 Significant Figures in Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–314
6.0 Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
6.1 Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
6.2 Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
6.3 Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
6.4 Tolerances for Production Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
7.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
7.1 Applications for Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
7.2 Standard Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
7.3 Rounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
7.4 Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–317
7.5 Stamping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–318
7.6 Plate Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–318
7.7 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–318
10/2007 C-III [M-1002] 311

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 con-
ventional 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 DEFINITIONS
this appendix:
Table H1. General definitions
Conventional unit The U.S. customary (English) units, such as the inch, pound, gal-
lon, etc.
Hard conversion When products are hard converted, the design of the item in SI
metric units results in a physical change and the product is not
interchangeable with earlier products built to the conventional
unit design.
SI unit The official abbreviation, in all languages, for the International
System of Units. The International System is not the old centime-
ter-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 writ-
ing 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 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 dis-
tance may have been 157.4 m; this number has four significant
digits.
Soft conversion When conventional units are soft converted, the physical dimen-
sions of an item remain unchanged and the units of measurement
are in SI terms.
C-III [M-1002] 312 10/2007

M-1002 APPENDIX H
3.0 SEQUENCE
The conversion of the tank car specifications from conventional units to SI units will be accom-
plished 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.
3.1 Stages
3.1.1 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.
3.1.2 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.
4.0 ITEMS NOT CONVERTED TO SI UNITS
4.1 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.
4.2 Obsolete Specifications
Obsolete specifications will not be converted to reflect SI equivalents, because the obsolete specifi-
cations authorize no new construction, but only maintenance, repair, and retest of existing equip-
ment.
4.3 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).
4.4 Appendix W
Established ASME conversions will be adopted for parallel material in Appendix W.
4.5 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.
4.6 Accepted Conventions
Do not convert
• truck sizes
• journal sizes
• valve nominal sizes
• pipe sizes
10/2007 C-III [M-1002] 313

APPENDIX H M-1002
5.0 STAGE 1 PHILOSOPHY

5.1 Standard Conditions
Standard conditions will be 14.696 psia (101.325 kPa abs) at 60 °F (15.56 °C).
5.2 Conversion Method
5.2.1 Conversions to SI units will be soft, as specified herein, with no deviations without
approval.
5.2.2 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.
5.3 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 phi-
losophy cannot be the sole criteria, because engineering judgments might introduce inconsisten-
cies 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 fol-
lowing conversion factors and significant figures will be used:
5.3.1 Mass
Pounds (lb) should be converted to kilograms (kg).
pound (lb) × 4.535 924 E – 01 = kg
• Up to 2200 lb—use three significant figures in kilograms (kg)
• From 2200 through 21,361 lb—use four significant figures in kilograms (kg)
• Over 21,361 lb—use five significant SI figures in kilograms (kg)
5.3.2 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 every-
thing 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
For conversions not involving set percentages, the following guidelines will be used:
• For pressures below 14.696 psi—use two significant SI figures in kilopascals (kPa)
• For pressures from 14.696 to 145 psi—use three significant SI figures in kilopascals (kPa)
• For pressures or stresses from 145 psi to 1459 psi—use four significant SI figures in kilo-
pascals (kPa)
• When kilopascals (kPa) exceed five figures—use 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.
C-III [M-1002] 314 10/2007
M-1002 APPENDIX H
5.3.3 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 fig-
ures
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

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

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

• Over 12 ft2—convert to three significant SI figures of square meters (m2)
ft2 × 9.290 304 E – 02 = m2

5.3.5 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 above—round to the appropriate number of SI figures of millimeters (mm) to
arrive at the desired accuracy for the stage of conversion covered in paragraph 3.1 of this
appendix
5.3.6 Temperature
Convert Fahrenheit temperatures to three significant figures of degrees Celsius.
(°F – 32)/1.8 = °C
5.3.7 Work
Foot pounds-force (ft · lbf) should be converted to joules (J).
ft · lbf × 1.355 818 E + 00 = J

• Up to 75 ft · lbf—convert to three significant SI figures of joules (J)
• For 75 ft · lbf and over—convert to four significant SI figures of joules (J)
10/2007 C-III [M-1002] 315

APPENDIX H M-1002
5.3.8 Force
Pounds force (lbf) should be converted to newtons (N).
lbf × 4.448 222 E + 00 = N

• Up to 1000 lbf—convert 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 4.3.4) 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).
5.3.9 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

5.3.10 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 fig-
ures.
Btu/(hr · ft2 · °F) × 2.044 176 E + 01 = kJ/(h· m2 · °C)

5.3.11 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)

5.3.12 Flow
Convert flow in cubic feet per minute (ft3/min) to three significant figures of cubic meters per sec-
ond (m3/s).
ft3/min × 4.719 474 E – 04 = m3/s

5.3.13 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

5.3.14 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 dec-
imal places.
C-III [M-1002] 316 10/2007

M-1002 APPENDIX H
6.0 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.
6.1 Stage 1
The following are examples for stage 1 tolerances:
• On Fig. E6, 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).”
6.2 Stage 2
The following is an example for stage 2 tolerances:
than 221 kPa to 262 kPa (35 psi ± 3 psi).”
6.3 Stage 3
The following is an example for stage 3 tolerances:
than 221 kPa to 262 kPa.”
6.4 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 7.3 below are followed.
7.0 GENERAL
7.1 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.
7.2 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.
7.3 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.
7.4 Formulas
7.4.1 Formulas in the appendices (such as found in Appendix E paragraphs 4.1, 6.2, 8.0, and 12.0)
will be revised per guidelines and a separate metric formula provided. A derivation and example
must be kept on file.
7.4.2 The derivation of the formulas in Appendix A will have a separate listing of metric dimen-
sions for clarity.
10/2007 C-III [M-1002] 317
APPENDIX H M-1002
7.5 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 capac-
ity as 0000 CU FT, or 0000 CU FT and 000 CU M.
7.6 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).
7.7 Miscellaneous
7.7.1 Do not mix symbols and words (e.g., do not use “square m”). Use “m2” or “square meters.”
7.7.2 As industrial standards are converted to metric, their effect on the Tank Car Specifications
will be evaluated.
7.7.3 Instead of converting references to letter-size sheets 8 1/2 × 11 in. to metric, “approximately
8 1/2 × 11 in.” will be specified.
7.7.4 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.
7.7.5 The conventional terms (dimensions) will be retained on the drawings and titles found in
Appendix E, such as Figs. E6, E7, E8, E19, and E19.2. They incorporate conventional dimensions
such as “Detail of Cover and Nozzle Joint for 20-in. Manway.” In such cases, there will be only con-
ventional units in the titles, without dualizing.
7.7.6 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

7.7.7 The number of significant figures specified are minimum. More significant figures will be
used when greater accuracy is required.
C-III [M-1002] 318 10/2007

M-1002 APPENDIX L
APPENDIX L
INTERIOR CLEANING, LINING, AND COATING
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–320
3.0 Application and Cleaning or Stripping of Linings and Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–321
3.1 Lining/Coating Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–321
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–321
3.3 Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–321
4.0 Personnel, Training, and Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–322
5.0 Valves and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–323
6.0 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–323
7.0 Application/Removal Reporting and Record Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–324
7.1 Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–324
7.2 Record Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–324
8.0 Coatings and Linings Applied for Corrosive Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–324
9.0 Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–325
10.0 Registration of Facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–325
11.0 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–325
10/2007 C-III [M-1002] 319

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 DEFINITIONS
this appendix:
Table L1. General definitions
Car owner The person or firm that owns the tank car (may also be the con-
tracting authority).
Cleaning Encompasses chemical, thermal, and mechanical techniques for
the preparation of the interior surfaces of tank car tanks and/or
valves and fittings.
Coating applicator The firm that is executing the specified work.
Contracting authority The coating/lining owner who is responsible for the approval of a
completed tank car coating/lining system, including periodic
inspection interval, test technique, and acceptance criteria.
Corrosive product Any product that has a corrosion rate as defined in paragraph 8.3
of this appendix.
Interior coating Any paint-type protective covering applied in one or more layers
to the interior of a tank car tank to act as a barrier between the
base metal and the commodity.
Interior lining Any sheet- or laminated-type material, glass, or fused metal
applied to the interior of a tank car tank to act as a barrier
between the base metal and the commodity.
Lining/coating owner The person or firm that owns the lining (may also be the contract-
ing authority).
NACE NACE International, formerly National Association of Corrosion
Engineers.
SSPC Steel Structures Painting Council.
Stripping Encompasses chemical, thermal, and mechanical techniques of
removal of existing linings or coatings from tank car tanks and/or
valves and fittings.
C-III [M-1002] 320 10/2007

M-1002 APPENDIX L
3.0 APPLICATION AND CLEANING OR STRIPPING OF LININGS AND COATINGS

3.1 Lining/Coating Materials
Table L2. 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 pro-
tective 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 chlo-
ride 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 mol-
(metal spray) ten 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.
3.2 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 func-
tion of the valves, fittings, seals, gaskets, insulation, cradle blocks, or other critical parts of the
tank car.
3.2.1 For lined tank car tanks, see additional requirements of DOT 179.201-3.
3.2.2 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.
3.3 Methods
3.3.1 Chemical Methods
3.3.1.1 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.
3.3.1.2 If subject to damage, all valves and fittings must be removed; however, if the bottom out-
let valve is too difficult to remove, it must be effectively protected, and the contracting authority
must be notified.
10/2007 C-III [M-1002] 321

APPENDIX L M-1002
3.3.1.3 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 oth-
erwise specified by the contracting authority.
3.3.2 Thermal Methods
3.3.2.1 When thermal methods are used for cleaning, application, or stripping of linings or coat-
ings, 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.
3.3.2.2 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 bot-
tom outlet valve is too difficult to remove, it must be effectively protected, and the contracting
authority must be notified.
3.3.2.3 Consideration must be given to all other car components if any procedure is to be used
that exposes such components to elevated temperatures.
3.3.2.4 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 con-
tracting authority must be notified.
3.3.3 Mechanical Methods
3.3.3.1 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 pro-
tected 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.
3.3.3.2 Tank shell thickness is critical. If a weld bead is blended by grinding, air hammer scrap-
ing, or contouring, care must be taken not to cause sharp notches or gouges and to avoid reduction
in tank shell plate thickness.
4.0 PERSONNEL, TRAINING, AND QUALIFICATION
4.1 Facilities that perform stripping, cleaning, and repair and/or apply interior protective coat-
ings 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 specifi-
cations who has been qualified in-house on the basis of demonstrated ability, achievement, experi-
ence, and training, in accordance with a written company practice.
4.2 Interior surfaces of tank cars subject to activities covered in paragraph 4.1 above shall be pre-
pared by personnel trained and qualified in accordance with a written company practice.
4.3 Protective interior coatings and/or linings shall be applied in accordance with the material
manufacturer’s application procedure and/or the contracting authority’s requirements by person-
nel qualified in accordance with a written company practice.
C-III [M-1002] 322 10/2007

M-1002 APPENDIX L
5.0 VALVES AND FITTINGS

5.1 Any pressure relief device, valve, or fitting removed from the tank and not disassembled may
be reapplied without retest of the valve or fitting.
5.2 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.
5.3 Except as provided for in paragraph 5.7 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 submit-
ted 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.
5.4 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.
5.5 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. E21A or Fig.
E21B 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.
5.6 When linings or coatings are to be applied to or stripped from valves or fittings, the remov-
able parts must be disassembled from the valves or fittings and each metallic part handled sepa-
rately, 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.
5.7 Seats of product valves must not be lined or coated unless specified by the car owner or the
coating/lining owner.
5.8 Threaded areas of operating parts must not be lined or coated.
6.0 COMPLIANCE
6.1 All interior cleaning, lining, or coating applications or stripping must be performed in accord
with the provisions of this specification.
6.2 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.
6.3 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 com-
pliance with all requirements of 49 CFR 179.7, this appendix, AAR specifications or rules, and
DOT/TC regulations.
6.4 The interior surface, prime coat, or adhesive layer and all subsequent coats of interior protec-
tive coatings and linings shall meet conditions of acceptance as agreed upon by the contracting
authority and the applicator, with consideration of the material manufacturer’s recommendations.
10/2007 C-III [M-1002] 323

APPENDIX L M-1002
6.5 The contracting authority shall prepare an inspection and test plan per 49 CFR 180.509.
7.0 APPLICATION/REMOVAL REPORTING AND RECORD RETENTION
7.1 Reporting
7.1.1 A report, including copies of final inspection report forms, must be furnished by the applica-
tor 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
7.1.2 No report is required for cleaning of tank cars.
7.2 Record Retention
7.2.1 The applicator shall retain inspection reports for each car for not less than five years.
7.2.2 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.
7.3 See paragraph 8.0 below for record retention requirements for car in-service/inspection repair
records.
8.0 COATINGS AND LININGS APPLIED FOR CORROSIVE SERVICE
8.1 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.
8.2 The lining/coating owner, unless otherwise agreed to, bears primary responsibility for compli-
ance with the requirements of this section.
8.3 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 mate-
rial shall be considered “corrosive.”
8.4 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, but in no case shall the inspection interval exceed 10 years.
8.5 In any given period, the most corrosive product transported shall dictate the inspection inter-
val, but in no case shall the inspection interval exceed 10 years.
8.6 New rubber linings must be spark-tested in accordance with a qualified procedure.
8.7 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, paragraphs 2.0 and 11.0, for tank repairs to pits and corrosion.
8.8 Records of in-service inspection/repair per this section must be kept by the contracting
authority for the life of the coating/lining.
8.9 Cars receiving coatings or linings per this section shall be marked in accord with Appendix C,
paragraph 3.3.3.
C-III [M-1002] 324 10/2007

M-1002 APPENDIX L
9.0 STENCILING
See Appendix C, Appendix D, and 49 CFR 180.509(i).
10.0 REGISTRATION OF FACILITIES
10.1 See Appendix B for the requirements to register or reregister facilities as Class L (install,
qualify, or repair interior linings and coatings in tank cars that transport corrosive commodities).
10.2 Certified facilities that are qualified as Class A, B, C, or D are considered to be qualified to
apply interior coating or lining to cars in corrosive service per this appendix.
10.3 Facilities that repair and/or apply coatings and linings for product purity only do not need to
be registered as Class L; however, Class G registration is required to remove and replace tank car
service equipment and gaskets.
11.0 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 Survey—Metals Section, sixth edition
10/2007 C-III [M-1002] 325

APPENDIX L M-1002
C-III [M-1002] 326 10/2007

M-1002 APPENDIX M
APPENDIX M
SPECIFICATIONS FOR MATERIALS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–329
1.2 Approved Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–329
1.3 Welded Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–329
2.0 Procedure for Securing Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–329
2.1 Application for Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–329
3.0 Approved Plate Materials for Tank Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–329
3.1 Carbon Steel Plate (Material Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–329
3.2 Aluminum Alloy Plate (Material Group 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–329
3.3 High Alloy Steel Plate (Material Group 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–330
3.4 Nickel Plate (Material Group 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–330
3.5 Nickel Alloy Steel Plate (Material Group 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–330
3.6 Manganese-Molybdenum Steel Plate (Material Group 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–330
3.7 Manganese-Silicon Steel Plate (Material Group 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–330
4.0 Approved Materials for Appurtenances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–330
4.1 Manway Covers for Nonpressure Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–330
4.2 Threaded Fasteners for Pressure Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–330
4.3 Threaded Fasteners for Pressure-Retaining Parts on Nonpressure Tank Car Tanks. . . . . . . . . . . C-III–331
4.4 Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–331
4.5 Castings for Valves and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–332
4.6 Miscellaneous Tank Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–334
4.7 Exterior and Interior Coil Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–336
4.8 Tank Bottom Reinforcing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–336
4.9 Quality of Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–337
5.0 Specification for High-Strength Carbon Manganese Steel Plates for Tank Cars—AAR TC128 . . . . C-III–338
5.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–338
5.2 General Condition for Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–338
5.3 Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–338
5.4 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–338
5.5 Tensile Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–339
5.6 Test Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–339
5.7 Number of Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–339
5.8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–339
5.9 Rejection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–339
5.10 Rehearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–339
10/2007 C-III [M-1002] 327

APPENDIX M M-1002
6.0 Specification for High-Strength Nine Percent Nickel Alloy Steel Plates, Double Normalized and
Tempered—AAR TC133C-III–340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–340
6.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–340
6.3 Impact Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–340
6.4 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–341
7.0 Specification for High-Strength Nine Percent Nickel Alloy Steel Plates, Water Quenched and
Tempered—AAR TC134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–341
7.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–341
7.3 Impact Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–342
7.4 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–343
8.0 Supplementary Specification for ASTM A516, Grade 70 Pressure Vessel Plates for Tank Car
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–345
8.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–345
C-III [M-1002] 328 10/2007

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 speci-
fications 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 M10.
Other approved plate materials are listed in Tables M10.1 through M10.6 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 Studs, bolts, and nuts securing pressure-retaining parts and tank anchors installed after
January, 2001, shall be of a specification that requires grade identification marks and manufac-
turer’s identification marks. Marks are to be stamped on the nut end of studs. Manway eyebolts
and socket head cap screws are specifically excluded. 15 CFR 280, Fastener Quality, requires regis-
tration of manufacturers’ marks.
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 Director—Tank 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 M10.1 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 specifica-
tions shown in Table M10.2 and with its indicated minimum tensile strength and elongation in the
welded condition.
10/2007 C-III [M-1002] 329

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 M10.3 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 M1. 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 M10.4 and with its indi-
cated 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 M10.5 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 spec-
ification shown in Table M10.6 and with the indicated minimum tensile strength and elongation in
the welded condition.
3.7 Manganese-Silicon Steel Plate (Material Group 1)
Manganese-silicon steel plate must be suitable for fusion welding and comply with the specifica-
tion shown in Table M10.7 and with the indicated minimum tensile strength and elongation in the
welded condition.
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 fit-
ting 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 prop-
erties must be considered in the design.
C-III [M-1002] 330 10/2007

M-1002 APPENDIX M
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, fasten-
ers 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 required for these grades. Impact values must be as specified in Table
W2 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 A320 Grades B8 Class 2; B8M Class 2; B8T Class 2; or B8C Class 2.
4.2.2.2 Nuts
ASTM A194.
4.3 Threaded Fasteners for Pressure-Retaining Parts on Nonpressure Tank Car Tanks
This paragraph lists materials, in addition to those in paragraph 4.2, that are approved for
threaded fasteners used to fasten valves, fittings, cover plates, and other pressure-retaining com-
ponents to nozzles, saddles, and flanges of nonpressure tank cars.
Carbon steel ASTM A307, Grade B, UNC 2A
studs, bolts,
and eyeboltsa/
Stainless ASTM A193, Grade B8, Class 1, UNC 2A
steel studs,
bolts, and
eyeboltsa/
a/ When applying a new stud, bolt, or eyebolt, new nuts must be applied.
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.
10/2007 C-III [M-1002] 331

APPENDIX M M-1002
4.5 Castings for Valves and Fittings

4.5.1 “Fittings” includes pressure relief devices; bottom outlet and washout nozzles; caps; reduc-
ers; 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, includ-
ing microstructure examinations and certification for all lots of castings.
Records of tests, microstructure examinations, and certification must be
maintained for five years and must be available for review by a representa-
tive of the Tank Car Committee.
ASTM A395, except repair plugging prohibited
Test requirements of ASTM A395, including the microstructure, are to be fol-
lowed. 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 require-
ments of ASTM A395. A minimum of one tension test shall be made from each
day’s 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 sam-
ple casting from the last metal poured from each ladle treated with the nodu-
larizing 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 require-
ments 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
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M-1002 APPENDIX M
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
10/2007 C-III [M-1002] 333

APPENDIX M M-1002
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 materi-
als are approved for general use, provided they are compatible with the tank plate materials of
paragraph 3.0, Table M10, 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 M10, and castings of paragraph 4.5 (all in this appendix) and may be used for the same pur-
pose, except that they may not be substituted for or used in place of required plate materials spec-
ified 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 not acceptable.
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 1008–1025,
inclusivec/
ASTM A576 Bars, Special Quality, AISI Grades 1008–1026, 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
C-III [M-1002] 334 10/2007

M-1002 APPENDIX M
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
1010–1025, inclusive
ASTM A513 Welded Mechanical Tubing, AISI and MT Grades
1008–1026, inclusived/
ASTM A519 Seamless Mechanical Tubing, AISI and MT Grades
1008–1026, 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.
10/2007 C-III [M-1002] 335

APPENDIX M M-1002
4.7 Exterior and Interior Coil Materials

4.7.1 In addition to the plate materials specified in Table M10, 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 fol-
lowing materials:
Carbon steel ASTM A516

ASTM A572
ASTM A612
TC128 Grade B
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M-1002 APPENDIX M
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 pat-
tern. 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 qual-
ification 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.
10/2007 C-III [M-1002] 337

APPENDIX M M-1002
5.0 SPECIFICATION FOR HIGH-STRENGTH CARBON MANGANESE STEEL PLATES

FOR TANK CARS—AAR 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 ft·lb (20.3 J) minimum average for three specimens, and 10
ft·lb (13.6 J) minimum for one specimen, at –50 °F (–45.6 °C) in the longitudinal direction of roll-
ing, 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 above for the energy absorption requirement
only.
5.3 Process
The steel must be made by the open hearth, electric furnace, or basic oxygen process.
5.4 Chemical Composition
The steel must conform to the chemical composition requirements prescribed in Table M2. All of
these elements, and any others intentionally added, must be reported on the Material Test Certifi-
cate. No intentional additions of boron or nitrogen are permitted.
Table M2. Chemical requirements for AAR TC128 Grade B steel
Element Heat Analysis Product Analysis
Carbon (max %) 0.24 0.26
Manganese (%) (≤ 3/4 in. thick) 1.00–1.65 1.00–1.70
(> 3/4" to 1 in. thick)
Phosphorus (max %) 0.025 0.025
Sulfur (max %) 0.015 0.015
Silicon (%) (≤ 3/4 in. thick) 0.15–0.40 0.13–0.45
(> 3/4 in. thick) 0.15–0.50 0.15–0.50
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 (%)a/ 0.015–0.060 0.015–0.060
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/ A minimum of 0.015% must be acid-soluble.
C-III [M-1002] 338 10/2007
M-1002 APPENDIX M
5.5 Tensile Properties

The material as represented by the test specimens must conform to the tensile properties pre-
scribed in Table M3.
Table M3. 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 percent-
age 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%.
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 con-
tract of the purchaser is being performed, to all parts of the manufacturer’s works that concern the
manufacture of the material. The manufacturer shall afford the inspector, free of charge, all rea-
sonable 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
purchaser’s 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 specifica-
tions will be rejected.
5.9.2 Material that shows injurious defects, subsequent to its original inspection and acceptance
at the manufacturer’s works, or elsewhere, will be rejected, and the manufacturer must be noti-
fied.
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.
10/2007 C-III [M-1002] 339

APPENDIX M M-1002
6.0 SPECIFICATION FOR HIGH-STRENGTH NINE PERCENT NICKEL ALLOY STEEL

PLATES, DOUBLE NORMALIZED AND TEMPERED—AAR 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 pre-
scribed in Table M4.
Table M4. 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/ 0.15–0.30
productb/ 0.013–0.32
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 M5 when the test is conducted at a temperature of –320 °F (–196 °C) or
–175 °F (–115 °C), whichever is specified.
Table M5. Impact properties for AAR TC133 steel—conventional 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 (ft·lb) for Both –175 °F and –320 °F
(mm) –175 °F –320 °F (ft·lb)
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 M6.
C-III [M-1002] 340 10/2007

M-1002 APPENDIX M
Table M6. Impact properties for AAR TC133 steel—SI 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 Con-
struction.
7.0 SPECIFICATION FOR HIGH-STRENGTH NINE PERCENT NICKEL ALLOY STEEL
PLATES, WATER QUENCHED AND TEMPERED—AAR 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
M7.
Table M7. 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/ 0.15–0.30
productb/ 0.13–0.32
a/ Heat and product analysis.
b/ Minimum of range not applicable when vacuum carbon deoxidation practice is used.
10/2007 C-III [M-1002] 341

APPENDIX M M-1002
7.3 Impact Properties

The transverse Charpy V-notch impact properties of the material must be not less than the values
prescribed in Table M8 when the test is conducted at a temperature of –320 °F (196 °C) or –175 °F
(–115 °C), whichever is specified.
Table M8. Impact properties for AAR TC134 steel—conventional units
Size of Specimen (ft·lb) for Both – 175 °F and –320 °F
(mm) –175 °F –320 °F (ft·lb)
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 M9.
Table M9. Impact properties for AAR TC134 steel—SI 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).
C-III [M-1002] 342 10/2007

M-1002 APPENDIX M
7.4 Reports
Mill test reports must be submitted to the AAR Tank Car Committee with the Certificate of Con-
struction.
Table M10. Approved materials for tanks fabricated by welding
The grouping of materials by P-number in this table does not imply that base materials of differ-
ent 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 treat-
ment, design and service requirements, and mechanical properties.
Table M10.1 Carbon steel platea/

Minimum Tensile Strength, Minimum Elongation in
Welded Conditionc/ 2- in. (50-mm) Weld Metal
(Longitudinal)
Material Specification P- numberb/ psi MPa %
Material Group 1
ASTM A516, Gr. 70 1 70,000 485 20
ASTM TC128, Gr. B d/ 81,000 560 19
Table M10.2 Aluminum alloy platee/

O Temper, Welded 2- in. (50-mm) O Temper,
Conditionc/ Welded Condition
(Longitudinal)
Material Specificatione/ P- numberb/ psi MPa %
Material Group 2
ASTM B209, Alloy 5052f/ 22 25,000 172 18
ASTM B209, Alloy 5083g/ 25 38,000 262 16
ASTM B209, Alloy 5086f/ 25 35,000 241 14
ASTM B209, Alloy 5154f/ 22 30,000 207 18
ASTM B209, Alloy 5254f/ 22 30,000 207 18
ASTM B209, Alloy 5454f/ 22 31,000 214 18
ASTM B209, Alloy 5652f/ 22 25,000 172 18
Table M10.3 High alloy steel plate

(Longitudinal)
Material Group 3
ASTM A240, Type 304 8 75,000 515 30
ASTM A240, Type 304L 8 70,000 485 30
ASTM A240, Type 316 8 75,000 515 30
ASTM A240, Type 316L 8 70,000 485 30
10/2007 C-III [M-1002] 343

APPENDIX M M-1002
Table M10.4 Nickel plate

(Longitudinal)
Material Group 4
ASTM B162 41 40,000 276 20
Table M10.5 Nickel alloy steel plate

(Longitudinal)
Material Group 7
AAR TC133h/i/ 11A SG-1 95,000 655 22
AAR TC134h/i/ 11A SG-1 95,000 655 22
Table M10.6 Manganese-molybdenum steel platea/

(Longitudinal)
Material Group 1
ASTM A302, Gr. B 3 80,000 550 20
Table M10.7 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/ A separate welding procedure qualification must be made for this material.
e/ Weld filler metal 5556 must not be used.
f/ For fabrication, the parent plate material may be O, H112, or H32 temper, but design calculations must
be based on minimum tensile strength shown.
g/ O temper only.
h/ Mill test reports must be submitted to the AAR Tank Car Committee with the Certificate of Construction.
i/ See paragraph 6.0 or paragraph 7.0 of this appendix, as applicable.
C-III [M-1002] 344 10/2007

M-1002 APPENDIX M
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 M11. All of these elements,
and any others intentionally added, must be reported on the Material Test Certificate. No inten-
tional additions of boron or nitrogen are permitted.
Table M11. Supplementary chemical requirements for ASTM A516 Grade 70
Element Heat Analysis Product Analysis
Carbon (max %)a/ b/ 0.23 0.25
Manganese (%)b/ 0.85–1.20 0.79–1.26
Phosphorus (max %) 0.025 0.025
Sulfur (max %) 0.015 0.015
Silicon (%) 0.15–0.40 0.15–0.45
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/ 0.015–0.060 0.015–0.060
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.
10/2007 C-III [M-1002] 345

APPENDIX M M-1002
C-III [M-1002] 346 10/2007

M-1002 APPENDIX P
APPENDIX P
TANK CAR COMMITTEE PROCEDURES
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–348
2.0 Accident Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–348
2.1 Accident Review Working Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–348
2.2 Agenda Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–348
2.3 Information Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–348
2.4 Working Group Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–348
10/2007 C-III [M-1002] 347

APPENDIX P M-1002
APPENDIX P
TANK CAR COMMITTEE PROCEDURES
1.0 INTRODUCTION
1.1 Scope
This appendix describes procedures to be used by the Tank Car Committee in conducting its busi-
ness. These procedures are only intended to supplement those of the Environmental and Hazard-
ous Materials Division. In case of conflict, the Division’s procedures will prevail.
2.0 ACCIDENT REVIEW
2.1 Accident Review Working Group
One of the standing working groups of the AAR Tank Car Committee will be the Accident Review
Working Group. It will be chaired by a representative from the AAR Bureau of Explosives. The
vice chairman will be a railroad representative from the Tank Car Committee. This working group
will be responsible for the continuous review of tank car performance in the accident environment,
both during transportation and during loading and unloading operations.
2.2 Agenda Items
Those accidents included on the agenda of this working group will be at the discretion of the work-
ing group chairman or at the request of the chairman of the Tank Car Committee.
2.3 Information Sources
In the process of reviewing each accident, the working group will consider information from the
following sources:
• Reports from AAR inspectors
• DOT Form 5800.1
• Reports from carriers involved in accidents
• Reports from shippers involved in loading accidents
• Information contained in local media reports
• RPI-AAR Safety Project reports
• Car owner’s Exhibit R–1 reports
2.4 Working Group Recommendations
After all relevant information has been received and duly considered, the working group will fur-
nish its recommendations to the Tank Car Committee. It will be the Tank Car Committee’s respon-
sibility to assign recommendations to other appropriate standing working groups, or, if warranted,
to form an ad hoc task force in order to prepare any needed specification changes or recommenda-
tions.
C-III [M-1002] 348 10/2007

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

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–352
1.2 Certified Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–352
1.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–352
1.4 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–352
3.0 Qualification of Personnel and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
3.1 Welders and Welding Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
3.2 Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
3.3 Nondestructive Testing (NDT) Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
3.4 Nondestructive Testing (NDT) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
4.0 Approvals and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
4.1 New Procedures or Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
4.2 Previously Approved Procedures and Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
4.3 Exhibit R–1 Report of Tank Repairs, Alteration, or Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–354
4.4 Exhibit R–2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs . . . . . . . . . . C-III–359
4.5 Availability of Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–365
5.0 Special Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–366
5.1 Hydrogen Fluoride, Anhydrous (AHF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–366
6.0 Damaged Stub Sills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–367
6.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–367
6.2 Cleaning for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–367
6.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–367
6.4 Inspection Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–367
6.5 Inspection Reporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–367
6.6 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–367
7.0 Acceptance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
8.0 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
8.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
8.2 Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
8.3 Low Hydrogen Electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
9.0 Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
10/2007 C-III [M-1002] 349

APPENDIX R M-1002

10.0 Repair of Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
10.1 Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
10.2 Welding of Cracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–369
10.3 Reinforcements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–369
10.4 Cracks in Dome Apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–369
10.5 Repair of Surface Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–369
11.0 Repair of Pits and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–370
11.1 Random Pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–370
11.2 Grouped Pits and General Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–370
11.3 Corrosion in or Adjacent to Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–371
11.4 Patch Plate Repair—AAR Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–371
11.5 Repair by Weld Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–371
11.6 Repair of Pressure Car Manway Gasket Grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–371
12.0 Repair of Deformation and Scoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–372
12.1 Dents or Buckles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–372
12.2 Pressing or Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–372
12.3 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–372
12.4 Scores and Gouges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–372
12.5 Wheel Burn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–372
13.0 Welded Inserts and Tank Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–373
13.1 When Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–373
13.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–373
13.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–373
13.4 Welded Inserts in Void Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–373
14.0 Riveted Repairs and Seal Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
14.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
14.2 Riveted Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
14.3 Seal Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
15.0 Connections Added or Relocated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
15.1 When Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
15.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
15.3 Removal of Rivet Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
15.4 Welding of Rivet Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
15.5 Nozzles and Domes on Welded Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–374
15.6 Permanent Closure of Bottom Outlet or Washout Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–375
15.7 Closures for Tongue-and-Groove Fittings Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–375
C-III [M-1002] 350 10/2007

M-1002 APPENDIX R

16.0 Attachments Added or Relocated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–375
16.1 Welded Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–375
16.2 Welding of Rivet Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–375
16.3 Anchor Rivet Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–375
16.4 Welded Bolster Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
16.5 Dome-to-Shell Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
16.6 Welding Stud Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
16.7 Repairs in Kind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
17.0 Attachment of Stub Draft Sill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
17.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
17.2 Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
18.0 Insertion of Interior Tank Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
18.1 Head Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
18.2 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
18.3 Voids Created . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–376
19.0 Nondestructive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–377
19.1 Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–377
19.2 Liquid Penetrant Examination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–377
19.3 Magnetic Particle Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–377
19.4 Ultrasonic Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–377
20.0 Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–378
20.1 When Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–378
20.2 Unit Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–378
20.3 Local Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–378
20.4 Postweld Heat Treatment Not Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–381
21.0 Hydrostatic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–381
22.0 Repairs to Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–381
23.0 Repairs to Fire-Damaged Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–382
24.0 Repairs to Tapped Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–382
25.0 Additional Welding to Tank Car Tanks After Initial Hydrotest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–383
25.1 Minor Welding to Tank Car Tanks Under Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–383
Fig. R13 Form SS-1 Report of Tank Car Stub Sill Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–390
10/2007 C-III [M-1002] 351

APPENDIX R M-1002
APPENDIX R
REPAIR, ALTERATION, AND CONVERSION TO TANK CAR TANKS
1.0 INTRODUCTION
1.1 Scope
Appendix R describes AAR requirements for repairs, alterations, or conversions to tank car tanks.
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 imperfec-
tion, the area shall be cleaned and welding performed in accord with Appendix W.
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 sur-
face 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 Appen-
dix T for methods employed.
C-III [M-1002] 352 10/2007

M-1002 APPENDIX R
2.0 DEFINITIONS
this appendix. The definitions of Appendix W, paragraph 2.0, also apply.
Table R1. General definitions
Alteration A change in tank or fittings that does not change the specification
but that does change the Certificate of Construction.
Blister A lesion in an AHF tank car tank of at least 1/4 in. (6.35 mm)
depth or height and of a diameter greater than 3 in. (76.2 mm).
Conversion A change in tank or fittings that changes the specification.
Crack Separation of material extending partially but not necessarily
completely through the cross section of the plate.
Dent A deformation that changes the tank contour from the original
manufactured state.
Fracture Complete separation of material extending through the entire
cross section of the plate.
Gouge A deformation caused by mechanical means that results in the
loss of parent or weld metal.
Injurious defect Any discontinuity (e.g., crack, lamination, pit, or hard spot) that
results in a change in the material’s physical properties so as not
to meet specification limits.
Pad An attachment welded directly to the tank under a bracket or
light structure for the purpose of preventing damage to the tank
through fatigue, over-stressing, denting, puncturing, or tearing.
Patch plate A steel plate applied as an overlay in a corroded area.
Pit A surface defect resulting from localized corrosion where the cav-
ity diameter at the 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 diameter.
Pits (random) Adjacent pits that are separated by a distance greater than or
equal to two times their average diameter and that do not exceed
two pits in any 6-in. × 6-in. (152-mm × 152-mm) area.
Reinforcing plate An attachment welded directly to the tank supporting a major
structural component for the purpose of preventing damage to the
tank through fatigue, over-stressing, denting, puncturing, or tear-
ing.
Repair Reconstruction of a tank to its original design function.
Score A narrow deformation caused by mechanical means wherein par-
ent or weld metal is upset and relocated.
Surface crack Separation of material extending 1/16 in. or less through the tank
plate thickness.
Wheel burn Damage to tank shell due to frictional contact with a rotating
wheel, resulting in metal flow and/or discoloration due to fric-
tional heat.
10/2007 C-III [M-1002] 353

APPENDIX R M-1002
3.0 QUALIFICATION OF PERSONNEL AND PROCEDURES

3.1 Welders and Welding Operators
Qualification of welders and welding operators must comply with Appendix W.
3.2 Welding Procedures
Qualification of welding procedures must comply with Appendix W.
3.3 Nondestructive Testing (NDT) Personnel
Qualification of NDT personnel must comply with Appendix T.
3.4 Nondestructive Testing (NDT) Procedures
Qualification of NDT procedures must comply with Appendix T.
4.0 APPROVALS AND REPORTS
4.1 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.
4.2 Previously Approved Procedures and Materials
4.2.1 When accident-related repairs, alterations, or conversions to tank car tanks are to be made
using previously approved procedures and materials, an Exhibit R–1 report, in compliance with
this appendix, must be submitted by the car owner or the company performing the work to the car
owner and the AAR Executive Director—Tank Car Safety (Director). No transmittal letter is
required. Companies with multiple facilities may submit Exhibit R–1 reports from one location.
4.2.2 Tank cars must not be returned to service until submission of the report. Failure to submit
the required Exhibit R–1 report may be cause for action by the AAR.
4.2.3 The Director may refer any Exhibit R–1 report to the Tank Car Committee for review. The
proponent and the car owner will be advised of this action.
4.2.4 If drawings depicting the previously approved procedures and materials have not been sub-
mitted 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.
4.3 Exhibit R–1 Report of Tank Repairs, Alteration, or Conversion
Exhibit R–1 (shown in Fig. R1) is required for reporting
• accident damage repairs to tank
• changes that affect the Certificate of Construction
• changes in authorized commodities
• changes in reporting mark and/or car number
• revisions or changes to valves, fittings, or pressure relief devices using previously approved
equipment or procedures
• previously approved alterations or conversions to additional cars
Information supplied will be entered into a database and analyzed in an effort to establish trends.
The AAR will maintain the database.
C-III [M-1002] 354 10/2007

M-1002 APPENDIX R
4.3.1 The owner or owner’s representative1/ is responsible for providing all requested informa-
tion, via computer diskette or e-mail, in a format approved by the AAR, to the AAR Executive
Director—Tank Car Safety, Association of American Railroads, 50 F Street NW, Washington, DC
20001-1564. Database structure and Exhibit R–1 in Microsoft Access® 97 format can be obtained
from the Director. Other software formats may be utilized if they maintain the same database
structure and can be successfully transmitted electronically, as determined by the Director. The
AAR is not to receive a hard copy of Exhibit R–1.
4.3.2 A separate Exhibit R–1 must be prepared for each tank car. Multiple cars are not permitted
on a single Exhibit R–1.
4.3.3 The information from the completed Exhibit R–1 forms must be retained in such a way that
a printable electronic copy or paper copy can be obtained and that changes to the original informa-
tion can be detected by the car owner or owner’s representative1/ as back-up documentation of the
work performed. The form used by the repair facility to provide information as to the work per-
formed should be as agreed upon by the two parties and need not be the Exhibit R–1 form provided
in this manual.
4.3.4 The following instructions corresponding to the line numbers and field name in the data-
base must be followed in filling out the report:
Instructions for Completing Exhibit R–1
Line Instruction
1. The report is the responsibility of the car owner and must be submitted by the car owner
or owner’s representativea/ to the Director. The report must be submitted at a minimum
once per month to the AAR in an electronic format (the electronic format requirements
must be obtained from or approved by the AAR).
2. Car reporting mark and number. A single report must be submitted for each car.b/
3. Name of the car owner or owner’s representativea/ reporting the work performed.
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. Car owner or owner’s representativea/ to enter the name of the car manufacturer.
9. Car owner or owner’s representative to enter the original AAR certificate number under
which the tank car was built. Note: enter the certificate number without dashes or spaces
(e.g., F799022C).
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.
a/ 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.
b/ When changing the reporting mark and/or number, show the new reporting mark and num-
ber at line 2. Record the previous mark and number at line 15.
c/ Enter a specification without dashes or spaces (e.g. DOT111A100W1).
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.
10/2007 C-III [M-1002] 355
APPENDIX R M-1002
Line Instruction
11. Car owner or owner’s representativea/ to enter the as-built car specification. If the car was
converted by Form AAR 4-2, or Exhibit R–1 was issued prior to this work, enter the con-
version specification.c/
12. Indicate the car specification following the work.c/
13. Indicate the stenciled car specification following the workc/
14. For repairs:
a. Describe the damage using Appendix R terminology (crack, fracture, dent, gouge, etc.)
and indicate the affected area (reference Fig. R2, Tank location chart) and dimensions
(e.g., 10-in. crack at ABS). When repairs are required due to an accident, list the rail-
road involved, the date of the accident, and the location of the accident, if the informa-
tion is available.
b. Describe the repair performed. List appropriate Appendix R references or previously
approved 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.”b/
16. List Tank Car Committee-approved drawings only. Drawings must closely 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 name and title of the facility (where work was performed) Quality Assurance
representative.
19. Print the name and title of the car owner or owner’s representativea/ and enter the date the
car owner or owner’s representativea/ approves the Exhibit R–1. Date format to be
MM/DD/YYYY.
a/ 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.
b/ When changing the reporting mark and/or number, show the new reporting mark and num-
ber at line 2. Record the previous mark and number at line 15.
c/ Enter a specification without dashes or spaces (e.g. DOT111A100W1).
C-III [M-1002] 356 10/2007

M-1002 APPENDIX R
Exhibit R-1 Report of Tank Repairs, Alteration or Conversion
EXHIBIT R-1 REPORT OF TANK REPAIRS, ALTERATION OR CONVERSION

1. To AAR Executive Director-Tank 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: (Ref. 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 QA Representative: Title:

Car Owners Representative: Title:
Date approved by Car Owner:
Rev. 12/1/2000
Fig. R1 Exhibit R-1 Report of Tank Repairs, Alteration, or Conversion
10/2007 C-III [M-1002] 357
APPENDIX R M-1002
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. R2 Tank location chart
C-III [M-1002] 358 10/2007

M-1002 APPENDIX R
4.4 Exhibit R–2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
4.4.1 Exhibit R–2 (shown in Fig. R3) is a means for collecting information pertaining to the fol-
lowing:
• tank buckle repairs
• tank corrosion repairs
• tank crack repairs
• center sill repairs
• repairs to stub sill, bolster, and cradle pad connections to tank
4.4.2 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.
4.4.2.1 The owner, or owner’s designee, is responsible for providing all requested information, via
computer diskette, to the Director. The Exhibit R–2 software is to be utilized to accomplish this.
The software and user’s guide are available from the Director by completing and submitting the
Exhibit R–2 Software Registration Form available at the above address. The AAR is not to receive
a hard copy of Exhibit R–2.
4.4.2.2 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 form 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.
4.4.2.3 The information from completed Exhibit R–2 forms must be retained, for back-up docu-
mentation of the work performed, by the car owner or the car owner’s 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 form at the back of this publication may be used as the hard copy, but is not man-
datory. 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 form provided in this
manual.
4.4.2.4 Exhibit R–2 data in the software is entered by line number. These line numbers corre-
spond to the entries on the Exhibit R–2 form provided in this manual. Each item of the form is to
be filled in as described below. Consult the R-2 Program User’s Guide before attempting to com-
plete 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 builder’s code as listed in Table R2.
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.
10/2007 C-III [M-1002] 359

APPENDIX R M-1002
Line Instruction
13. Enter the manufacturer’s stub sill design style designation and corresponding builder code
as shown in Table R2.
14. Indicate whether or not the car is jacketed.
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 Figs. R3.1 through R3.6 on page C-III–363. If “(O)-Other” is indicated, ex-
plain in line 24—Comments.
17. Enter the code for the type of failure repaired. If “(H)-Other” is indicated, explain in
line 24—Comments.
18. Enter the code for the suspected cause of failure. Avoid indicating “(D)-Unknown” if at all pos-
sible.
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:
10.2 Welding of Cracks 11.5 Weld Overlay

10.5 Repair of Surface Cracks 12.1 Dents/Buckles
11.1 Random Pits 13.2 Inserts
11.2 Grouped Pits/Corrosion Field Manual of the AAR Interchange Rules, Rule 57—Center Sill
11.3 Corrosion at Welds Field Manual of the AAR Interchange Rules, Rule 82 (Weld Sill)
11.4 Patch Plate Repair Replaced in kind
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 24—Comments.
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 lo-
cation. See Fig. R3 on page C-III–362. Dimensions are not required.
22. Enter the code and dimensions for the location of repair. See page C-III–362 for guidance.
23. Enter the code for the method of inspection utilized to detect the defect. If “Other” is indicated,
explain in line 24—Comments.
24. Provide additional information that may be relevant, including observations that may pre-
clude similar failures in the future. Information must be furnished here if “Other” was select-
ed in lines 16, 17, 19, or 23.
25. Sign and date the form and print your name and title.
C-III [M-1002] 360 10/2007

M-1002 APPENDIX R
Exhibit R-2 Report of Nonaccident-related Buckles, Corrosion, and Crack
EXHIBIT R–2 (PAGE 1 OF 3)

Repairs
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 Shell—Exterior (C)-Tank Head—Interior (D)-Tank Head—Exterior (E)-Cen-
ter Sill—Web (F)-Center Sill—Flange (G)-Center Sill—Both (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)-Weld—Bolster 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)-Corrosion—Random Pits (E)-Corrosion—Grouped
Pits (F)-Corrosion—Adjacent to Weld (G)-Corrosion—General (H)-Other (Explain in Item 24. Comments)
(I)-Corrosion—Bathtub 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)-11.1 (D)-11.2 (E)-11.3 (F)-11.4 (G)-11.5 (H)-13.2 (I)-Replaced in Kind (J)-Precedent Certif-
icate of Construction, Number: a. ________; b. ________; c. ________; d. ________; e. ________; f. ________
(K)-12.2 Buckles (L)-Rule 82 Weld Sill (M)-Rule 57 (O)-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: Original—Car owner; Diskette copy—AAR
Fig. R3 Exhibit R–2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
10/2007 C-III [M-1002] 361
APPENDIX R M-1002

Fig. R3 Exhibit R–2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs (continued)
C-III [M-1002] 362 10/2007

M-1002 APPENDIX R

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
Fig. R3 Exhibit R–2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs (continued)
10/2007 C-III [M-1002] 363

APPENDIX R M-1002
Table R2. Builder and design style identification (page 1 of 2)

Exhibit R–2 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
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/
Texana Tank Car & Mfg. TEX TEX (Fig. R3.1)
C-III [M-1002] 364 10/2007

M-1002 APPENDIX R
Table R2. Builder and design style identification (page 2 of 2)

Exhibit R–2 Designation for:
Builder Name
Builder Stub Sill Design Style
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)
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
4.5 Availability of Forms

Reproducible copies of Exhibit R–1 and R–2 forms are located at the back of this publication.
10/2007 C-III [M-1002] 365

APPENDIX R M-1002
5.0 SPECIAL REQUIREMENTS

For special commodity requirements, see Tariff No. BOE-6000. Also refer to the special commodity
requirements in Chapter 2.
5.1 Hydrogen Fluoride, Anhydrous (AHF)
5.1.1 Existing tank cars placed into anhydrous hydrogen fluoride service must conform to Chap-
ter 2, paragraph 2.1.4.
5.1.2 Weld repair of blisters in AHF tank cars shall be repaired by insert in accordance with
paragraph 13.0 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 treat-
ment 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 (see Appendix W,
paragraph 13.7.1 for the formula for carbon equivalence). 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 Hardness—Vickers) 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.
5.1.2.1 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 sur-
face 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 loca-
tions 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.
5.1.2.2 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 5.1.2.1 above.
C-III [M-1002] 366 10/2007

M-1002 APPENDIX R
6.0 DAMAGED STUB SILLS

6.1 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
6.2 Cleaning for Inspection
Welds must be cleaned and made accessible consistent with the inspection technique.
6.3 Inspection
6.3.1 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 reinforce-
ment 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.
6.3.2 The draft gear pocket must be inspected.
6.4 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.
6.5 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. R13).
6.6 Repairs
6.6.1 Repair per owner’s instructions or in kind to restore original design.
6.6.2 Straighten bent sills.
6.6.3 Reinspect all repairs.
6.6.4 Repair all cracks, including seal welds.
10/2007 C-III [M-1002] 367

APPENDIX R M-1002
7.0 ACCEPTANCE CRITERIA

7.1 Welding
7.1.1 All welded repairs to tank car tanks must conform to the applicable sections of Appendix W,
paragraphs 3.0, 14.0, and 15.0.
7.1.2 All welded repairs to related components or assemblies must conform to the applicable sec-
tions of AWS D15.1 (latest revision).
7.2 NDT
All nondestructive testing results shall meet the requirements of Appendix W, paragraph 11.0.
8.0 MATERIALS
8.1 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.
8.2 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.
8.3 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 15.11.
9.0 HARDNESS TESTS
Butt-welded repairs in pressure car tanks that are constructed of Table M10.1 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.
10.0 REPAIR OF CRACKS
10.1 Methods
Tank cracks may be repaired by one of the following methods:
10.1.1 By preparation and welding of the crack in compliance with Fig. R5. An interior or exterior
reinforcement patch may be applied over the repaired area, if deemed necessary.
10.1.2 By removal of the defective area and application of a welded insert, except as noted in
paragraph 14.2.2 below.
10.1.3 On riveted tanks only, by removal of the defective area and application of a riveted patch.
C-III [M-1002] 368 10/2007

M-1002 APPENDIX R
10.2 Welding of Cracks

10.2.1 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. Except as noted below, the crack groove must
be welded, and a groove may be back chipped, ground, air-carbon arc gouged, or plasma arc gouged
from the opposite side and a butt-welded repair made, followed by radiography or ultrasonic test-
ing, in accord with Appendix W, paragraph 11.0, and postweld heat treatment. To ensure complete
removal of the defect, a liquid penetrant or magnetic particle test on interior and exterior surfaces,
in accord with Appendix W, paragraph 11.0, is required.
10.2.2 If, after complete removal of the crack, the defect is found to be 3/16 in. (4.76 mm) or less
in depth and 6 in. (152 mm) or less in length, then radiography or ultrasonic testing and local
postweld heat treatment are not required, except all crack repairs to pressure cars must be
radiographed or ultrasonically tested in accord with Appendix W, paragraph 11.0, and postweld
heat treated.
10.2.3 On aluminum tanks, flame gouging or air-carbon arc gouging must not be used.
10.3 Reinforcements
Reinforcements may be applied to areas where cracks have occurred; however, cracks must first be
repaired by welding, as prescribed above, and radiographed or ultrasonically tested in accord with
Appendix W, paragraph 11.0. 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.
10.4 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 pre-
scribed in paragraph 10.2.2 above. See Fig. R7. If it is necessary to remove the tank shell sheet, see
paragraph 13.0 or 14.0 below.
10.5 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 pene-
trant method.
10/2007 C-III [M-1002] 369

APPENDIX R M-1002
11.0 REPAIR OF PITS AND CORROSION

11.1 Random Pits
11.1.1 Random pits may be repaired by chipping or grinding to sound metal.
11.1.2 If the sound metal is less than the minimum allowable thickness, restoration of the
affected areas to at least the minimum allowable thickness by weld buildup or insert is required.
Postweld heat treatment and radiography or ultrasonic testing are not required for restoration by
weld buildup, except all random pit repairs by welding to carbon steel pressure car tanks must be
postweld heat treated. If repairs are made by insert, the requirements of paragraph 13.0 below are
to be followed.
11.2 Grouped Pits and General Corrosion
11.2.1 Corroded areas or grouped pits whose total area of repair is equal to or less than 2 ft2 may
be repaired by chipping or grinding to sound metal.
If the sound metal is less than the minimum allowable thickness, restoration of the affected areas
to at least the minimum allowable thickness by weld buildup or insert is required. Postweld heat
treatment is required. After postweld heat treatment, magnetic particle or liquid penetrant test is
required for weld buildup over 3/16-in. depth. If the depth after cleaning to sound metal exceeds
50% of the minimum allowable thickness, paragraph 11.2.5 below applies. If repairs are made by
insert, the requirements of paragraph 13.0 below are to be followed.
11.2.2 Corroded areas of grouped pits whose total area of repair is more than 2 ft2 and average
pit depth is equal to or greater than the lesser of 1/8 in. or 20% of the original base metal thickness
must be repaired by removing the affected area and applying an insert. See paragraph 13.0 below.
11.2.3 Corroded areas or grouped pits whose total area of repair is more than 2 ft2 and average
pit depth is less than 1/8 in. and less than 20% of the original base metal thickness may be
repaired by chipping or grinding to sound metal.
treatment is required. If repairs are made by insert, the requirements of paragraph 13.0 below are
to be followed.
11.2.4 Corroded grooves longitudinal to the tank or striations around the periphery of the tank
may be repaired by chipping or grinding to sound metal.
treatment is required. After postweld heat treatment, magnetic particle or liquid penetrant
inspection is required. Radiography or ultrasonic testing is not required, except, if the depth after
cleaning to sound metal exceeds 50% of the minimum allowable thickness, paragraph 11.2.5 below
applies. If repairs are made by insert, the requirements of paragraph 13.0 below are to be followed.
11.2.5 In all cases, for repair of grouped pits, general corrosion, corroded grooves longitudinal to
the tank, or striations around the periphery of the tank, if the corroded area after cleaning to
sound metal is deeper than 50% of the required minimum tank shell or head thickness after form-
ing per 49 CFR 179, then radiography or ultrasonic examination is required. If welds or overlay
are radiographed or ultrasonically examined, then magnetic particle and liquid penetrant testing
may be deleted.
11.2.6 All weld overlay repairs on a tank car tank bottom shall be examined by the liquid pene-
trant or magnetic particle testing method. This area of examination shall include the entire 6 in. of
plate beyond the edge of the overlay on all sides of the overlay. All examinations are to be per-
formed after final postweld heat treatment.
C-III [M-1002] 370 10/2007

M-1002 APPENDIX R
11.3 Corrosion in or Adjacent to Welds

Corrosion in or adjacent to welds may be repaired by welding. Radiography, ultrasonic examina-
tion, and postweld heat treatment are not required if the corroded area does not exceed 3/8 in.
(9.52 mm) in width and 3/16 in. (4.76 mm) in depth, length not limited, after all corrosion damage
has been removed and the damaged area is ready for welding. If these dimensions are exceeded,
the repair must be postweld heat treated, except all repairs by welding to carbon steel pressure car
tanks must be postweld heat treated. If the corroded area, after cleaning to sound metal, is deeper
than 50% of the required minimum tank shell or head thickness after forming per 49 CFR 179,
then radiography or ultrasonic examination also is required.
11.4 Patch Plate Repair—AAR Tanks
11.4.1 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. minimum (25.4-mm) 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.
11.4.2 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.
11.5 Repair by Weld Buildup
11.5.1 Nonpressure carbon steel tank car tanks made from A515 Grade 70, A285 Grade C, or
A516 Grade 70 material may be restored by weld buildup. Radiography or ultrasonic testing is not
required. Postweld heat treatment is accomplished by the temper bead technique, provided the fol-
lowing conditions are met:
11.5.1.1 The weld buildup thickness must not exceed 50% of the minimum required thickness of
the tank at the point of repair.
11.5.1.2 Welding must be performed by a temper bead technique and must be qualified in accord
with Appendix W, paragraph 13.7. All heat-affected zones adjacent to buildup welds must be tem-
pered by the heat of successive passes. Consistency of tempering is accomplished by overlapping
beads by the same amount, such as one-fourth bead width overlap (see Fig. R12). The final (untem-
pered) bead must either be removed by grinding or subjected to thermal postweld heat treatment.
11.5.2 If the tank shell is pierced during the buildup process, repairs must be made in accord
with paragraph 10.0 above.
11.5.3 For any area repaired by weld buildup that is coincident with any of the repairs described
under paragraphs 10.2, 11.1, 11.3, or 12.4 in this appendix, radiography or ultrasonic examination
and postweld heat treatment are required.
11.5.4 Weld buildup repair without postweld heat treatment is prohibited on pressure tank car
tanks and non-pressure tank car tanks made from TC128 Grade B material.
11.5.5 All weld overlay repairs on a tank car tank bottom shall be examined by the liquid pene-
trant or magnetic particle testing method. This area of examination shall include the entire 6 in. of
plate beyond the edge of the overlay on all sides of the overlay. All examinations are to be per-
formed after final postweld heat treatment.
11.6 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.
Welding must be performed by an AAR-qualified welder in a certified facility. Postweld heat treat-
ment is not required. A leakage pressure test per 49 CFR 180.509(j) is required to ensure the
integrity of the manway securement.
10/2007 C-III [M-1002] 371
APPENDIX R M-1002
12.0 REPAIR OF DEFORMATION AND SCORING

12.1 Dents or Buckles
Dents or buckles may be repaired, provided the procedure by which the areas are restored to con-
tour does not damage the material or alter the physical properties of the material beyond specifi-
cation limits.
12.2 Pressing or Jacking
12.2.1 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 14.6. Excessive heating of the metal shall be avoided. For car-
bon steel, the maximum temperature is 1250 °F (677 °C).
12.2.2 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 11.0. All weld seams in the deformed area and
adjacent within 2 in. (50.8 mm) of the deformed area must be radiographed or ultrasonically exam-
ined for the entire weld seam length and 2 in. (50.8 mm) beyond the deformed area.
12.3 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.
12.4 Scores and Gouges
12.4.1 Scores or gouges associated with dents must be prepared first by restoring the dented area
to original contour, per paragraph 12.2 above. The score or gouge must then be prepared by grind-
ing or by air-carbon arc or plasma arc gouging, to sound metal, removing all upset metal and inju-
rious 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 11.0.
12.4.2 If the plate has been reduced below the limitations shown below, it must be restored or
replaced in accord with the applicable reference.
• All DOT specification tanks—49 CFR 180.509
• AAR specification tanks transporting regulated hazardous commodities—49 CFR 180.509
• AAR specification tanks transporting nonregulated commodities—M-1002 Appendix D
The thickness may be restored by fusion welding and by grinding the surface flush. If the repair
welds do not exceed any one of the limits of 3/16 in. (4.76 mm) deep, 3/8 in. (9.52 mm) wide, or 24
in. (610 mm) long, postweld heat treatment is not required, provided adjacent scores are separated
by at least six times the shell thickness. Repairs to carbon steel tanks in excess of the above limita-
tions must receive postweld heat treatment, except all repairs by welding to carbon steel pressure
car tanks must be postweld heat treated. If the score or gouge, after cleaning to sound metal, is
deeper than one half the metal thickness, then radiography or ultrasonic examination is also
required.
12.5 Wheel Burn
12.5.1 A shell damaged as a result of wheel contact (burn) must be repaired by one of the follow-
ing methods:
12.5.2 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 11.0.
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M-1002 APPENDIX R
12.5.3 Wheel burns that do not exceed 3/16 in. (4.76 mm) in depth and 12 in. (305 mm) in length
can be repaired by fusion welding, and the surface ground flush. Before welding, the wheel burn
must be prepared by grinding, air-carbon arc gouging, or plasma arc gouging to sound metal,
removing all upset metal and injurious defects. After preparation, the area must be examined by
magnetic particle or liquid penetrant method, in accord with Appendix W, paragraph 11.0. Radiog-
raphy or ultrasonic examination and postweld heat treatment of the repaired area are required.
12.5.4 Wheel burns in excess of the limits in paragraphs 12.5.2 and 12.5.3 above must be
repaired by insert.
13.0 WELDED INSERTS AND TANK SECTIONS
13.1 When Permitted
13.1.1 On riveted tanks, welded inserts and tank sections may be applied if the welding can be
locally postweld heat treated.
13.1.2 On fusion-welded tanks, welded inserts and sections may be applied to any part of the
tank shell and heads.
13.1.3 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.
13.2 Procedure
13.2.1 The insert or plate must have a double-welded butt joint with 1-in. (25.4-mm) minimum
corner radius. The insert must restore original contour. See paragraph 20.0 below for postweld
heat treatment requirements.
13.2.2 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 physical and chemical properties and be listed in Appendix M,
Table M10.1.
13.2.3 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 and radiographed or ultrasonically tested in accord with Appendix W,
paragraph 11.0.
13.3 Inspection
Butt welds in shells, including tank heads, must be inspected. For the purpose of this section,
“inspection” refers to either radiography (RT) or ultrasonic testing (UT). 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 radiographic requirements shall comply with
Appendix W, paragraph 19.3.
13.4 Welded Inserts in Void Areas
Indentations or cracks in void areas of compartmented tanks may be repaired by application of an
insert, per Fig. R9. The backing strip must be made in one piece, securely clamped and tack-
welded before being utilized as a backing. The root passes must be thoroughly cleaned and tested,
using either the magnetic particle or liquid penetrant method, in accord with Appendix W,
paragraph 11.0, before applying subsequent weld passes. Tack welds must be removed prior to
application of root passes. Postweld heat treatment is required in accord with paragraph 20.0
below.
10/2007 C-III [M-1002] 373

APPENDIX R M-1002
14.0 RIVETED REPAIRS AND SEAL WELDING

14.1 Requirements
Riveted repairs must be made in compliance with the specification covering original tank construc-
tion.
14.2 Riveted Patches
14.2.1 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.
14.2.2 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.
14.3 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).
15.0 CONNECTIONS ADDED OR RELOCATED
15.1 When Permitted
Additional and relocated connections, such as nozzles, may be added or relocated on dome heads
and tank shells, in compliance with Figs. E20.1 through E20.12.
15.2 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.
15.3 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.
15.4 Welding of Rivet Holes
When necessary to close rivet holes, the holes must be plug-welded and radiographed or ultrasoni-
cally tested, in accord with Appendix W, paragraph 11.0, after removing the back-up strip. See Fig.
R6. Plug welds must be ground smooth if tanks are to be lined.
15.5 Nozzles and Domes on Welded Tanks
15.5.1 Nozzles and domes attached to a tank shell must be designed to meet the reinforcement
requirements of Appendix E.
15.5.2 Approved nozzle and dome designs and welded attachments are shown in Appendix E,
Figs. E20.1 through E20.12.
15.5.3 Other designs of nozzles and domes and their attachments to tanks may be used, provid-
ing reinforcement meets the requirements of Appendix E and welding is equivalent to that shown
for designs in Figs. E20.1 through E20.12.
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M-1002 APPENDIX R
15.5.4 When nonpressure tank cars are altered or repaired, or when pressure tank cars are con-
verted to nonpressure status, insert-type nozzle applications may be made, utilizing partial pene-
tration welds per Fig. R10, 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)
15.5.5 When nonpressure cars arc altered or repaired, or when pressure cars are converted to
nonpressure status, lap joint nozzle applications may be made, in accord with Fig. R11.
15.5.6 Postweld heat treatment is required.
15.6 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.
15.7 Closures for Tongue-and-Groove Fittings Interfaces
When fittings equipped with tongue-and-groove interfaces are removed from a pressure car man-
way cover plate, they must be replaced using tongued blind flanges that are in accord with Figs.
E27 or E28. 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.
16.0 ATTACHMENTS ADDED OR RELOCATED
16.1 Welded Attachments
16.1.1 Exterior or interior brackets, supports, and reinforcement bar pads may be fillet-welded to
a tank shell without postweld heat treatment, provided welds do not exceed 3 in. (76.2 mm) in
length for any intermittent welding (intermittent or backstep sequence welding permitted) and
the total lineal welds do not exceed 24 in. (610 mm) per bracket, support, or reinforcing bar pad.
Throat thickness of welds must not exceed 1/4 in. (6.35 mm). All attachment welds to carbon steel
pressure car tanks must be postweld heat treated.
16.1.2 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 16.0,
must be met. The fillet welds must meet Appendix W, paragraph 15.9, 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.
16.2 Welding of Rivet Holes
See paragraph 15.4 above.
16.3 Anchor Rivet Caps
One-piece anchor rivet caps may be attached to a tank shell by fillet welding, provided welds do
not exceed 3 in. (76.2 mm) in length, for any intermittent welding. Completed welds must be made
by use of the skip or step-back method. Throat thickness of welds must not exceed 1/4 in.
(6.35 mm). A tapped hole must be provided through the tank shell under each cap to permit mak-
ing an air test. Each test hole must be tightly closed after completion of the test with an approved
plug. Caps must be tested by applying air pressure of 100 psi (689 kPa) and must be tight against
leakage.
10/2007 C-III [M-1002] 375

APPENDIX R M-1002
16.4 Welded Bolster Supports

Welded steel tanks mounted on underframes may be modified by attaching welded bolster sup-
ports to tank bottom reinforcement plates or directly to the tank, securely fastened to underframe,
with necessary provision for expansion and contraction. When all welding to the tank has been
completed, the tank must be postweld heat treated in compliance with paragraph 20.0 below.
16.5 Dome-to-Shell Attachments
See paragraph 15.5 above.
16.6 Welding Stud Attachments
If welding studs are applied by the stud welding process, the tank must be postweld heat treated.
If applied by fillet welding, postweld heat treatment is not required, provided the requirements of
paragraph 20.4.3 below are met, except carbon steel pressure car tanks must be postweld heat
treated.
16.7 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.
17.0 ATTACHMENT OF STUB DRAFT SILL
17.1 Procedure
Stub draft sills may be fusion-welded to bottom reinforcement plates. Tanks mounted on under-
frames also may be modified by attaching welded stub draft sills.
17.2 Postweld Heat Treatment
When all welding to the tank has been completed, regardless of attachment design, the tank must
be postweld heat treated in compliance with paragraph 20.0 below.
18.0 INSERTION OF INTERIOR TANK HEADS
18.1 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.
18.2 Welding
Welding of inserted heads must be performed in accord with Appendix E, paragraph 7.0. Welding
of the replaced head must be performed in accord with paragraph 13.0 above.
18.3 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.
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M-1002 APPENDIX R
19.0 NONDESTRUCTIVE TESTING

19.1 Radiography
19.1.1 When required
Radiographic examination of tank car tanks that are steel-stamped to DOT specifications must be
in accord with paragraph 19.1.2 below, whether tank cars are stenciled AAR or DOT. Radiographic
examination is not required for tank car tanks steel-stamped to AAR specifications.
19.1.2 Procedure
Butt welds must be examined throughout their entire length by radiography, in accord with
Appendix W, paragraph 11.0. When a deformation has been removed, all weld seams in that area
and 2 in. (50.8 mm) beyond must be radiographed.
19.1.3 Production Weld Repairs
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 radiography
must comply with Appendix W, paragraph 19.3.
19.1.4 Interpretation
Interpretation of weld defects on radiographs must comply with Appendix W.
19.1.5 Retention of Films
Radiographs must be retained for 5 years.
19.1.6 High Alloy Steel Tanks
For tanks fabricated from type 430A material, repair welds and intersections of all longitudinal
and circumferential double-welded butt joints in the tank must be radiographed after postweld
heat treatment using the acceptance standards specified in Appendix W, paragraph 11.0.
19.2 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 11.3.2 and 11.3.3.
19.3 Magnetic Particle Examination
Magnetic particle inspection shall be performed in accord with Appendix T. Evaluation and accep-
tance of indications shall be in accord with Appendix W, paragraphs 11.4.2 and 11.4.3.
19.4 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 11.5.2.
19.4.1 When Required
Ultrasonic testing of tank car tanks that are steel-stamped to DOT specifications must be in
accord with paragraph 19.4.2 below, whether tank cars are stenciled AAR or DOT. Ultrasonic
examination is not required for tank car tanks steel-stamped to AAR specifications.
19.4.2 Procedure
Butt welds must be examined throughout their entire length by ultrasonic testing in accord with
Appendix W, paragraph 11.0. When a deformation has been removed, all weld seams in that area
and 2 in. (50.8 mm) beyond must be ultrasonically tested.
19.4.3 Interpretation
Interpretation of weld defects for ultrasonic testing must comply with Appendix W.
19.4.4 Retention of Records
Ultrasonic testing records must be retained for 5 years.
10/2007 C-III [M-1002] 377

APPENDIX R M-1002
19.5 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.
20.0 POSTWELD HEAT TREATMENT
20.1 When Required
20.1.1 Except as noted in paragraph 20.4 below, postweld heat treatment is required for tank car
tanks that are steel-stamped to DOT specifications, whether they are stenciled AAR or DOT.
Postweld heat treatment is not required for tank car tanks steel-stamped to AAR specifications.
20.1.2 Any repair or alteration involving welding on a carbon steel pressure car tank must be
postweld heat treated.
20.2 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 17.0. See
paragraph 19.1.6 above for special radiography requirements for tanks fabricated from Type 430A
material.
20.3 Local Postweld Heat Treatment
20.3.1 In lieu of unit postweld heat treatment for carbon steel tanks, local postweld heat treat-
ment (LPWHT) per requirements below may be employed by certified facilities or contracted out to
approved subcontractors. If subcontractors are used, an AAR Exhibit B–1 Subcontractor Evalua-
tion Sheet is to be completed and retained by the certified facility. Approved stress-relieving equip-
ment 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.
20.3.2 Requirements for Local Postweld Heat Treatment (LPWHT)
20.3.2.1 Minimum Equipment Requirements
• Automatic temperature recorder
• Heater control unit
• Heaters and insulation
• Control and monitor thermocouples and control cables
20.3.2.2 Heat Treating Procedure, Minimum Requirements
20.3.2.2.1 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 oppo-
site side of the heating area are to be covered with thermal insulation to reduce heat loss.
20.3.2.2.2 To avoid ignition and fire, sufficient insulation or lining should be removed from the
LPWHT area.
20.3.2.2.3 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.
20.3.2.2.4 Each heater circuit or control zone is to have a control thermocouple placed near the
geometric center of the heating zone. (See Fig. R4.)
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M-1002 APPENDIX R
20.3.2.2.5 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.
20.3.2.2.6 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.
20.3.2.2.7 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.
20.3.2.2.8 LPWHT cycle temperatures and time are to be in accordance with Appendix W, para-
graphs 17.3 and 17.4.
20.3.2.3 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.
20.3.2.4 Documentation
20.3.2.4.1 A written local postweld heat treatment procedure is required.
20.3.2.4.2 Temperature time record is to be recorded on a strip chart or record showing thermo-
couple location, car number, and technician signature.
20.3.2.5 Heat Treating Technicians
20.3.2.5.1 LPWHT technicians shall be qualified through a written training program conducted
either in-house or by a recognized subcontractor.
20.3.2.5.2 The training program shall, as a minimum, cover the following areas: safe use of
equipment, equipment calibration, thermocouple/insulation placement, and AAR temperature lim-
its.
20.3.2.5.3 Technicians shall demonstrate competence in completing tasks outlined in the com-
pany's written LPWHT procedure.
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APPENDIX R M-1002
XS
ONE PAD—ONE CIRCUIT
XS
XS OS XS OS
XS
TWO PADS—TWO CIRCUITS TWO PADS—ONE CIRCUIT FOUR PADS—ONE CIRCUIT
S
XS
O
XS X
X = CONTROLLING THERMOCOUPLE
S
XS O = MONITORING THERMOCOUPLE
O S = SPARE THERMOCOUPLE
THREE PADS—THREE CIRCUITS THREE PADS—ONE 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 TECHNICIAN’S 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
MADE DIRECTLY TO THE TANK SHELL.
Fig. R4 Postweld heat treatment thermocouple placement and use
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M-1002 APPENDIX R
20.4 Postweld Heat Treatment Not Required

Except as noted in paragraph 20.1.2 above, postweld heat treatment may be omitted under the
following conditions:
20.4.1 When specifically permitted in the foregoing paragraphs. (See 11.1, 12.4, 16.1, and 16.6.)
20.4.2 For single- or double-butt welds not exceeding 3 in. (76.2 mm) in length.
20.4.3 For intermittent fillet welds (skip or step-back welding permitted) not exceeding 3 in.
(76.2 mm) in length, 1/4 in. (6.35 mm) in throat thickness, when the total length of these welds per
attachment does not exceed 24 in. (610 mm).
20.4.4 Aluminum tank welds must not be postweld heat treated.
20.4.5 When not required for new car construction.
21.0 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
22.0 REPAIRS TO ANCHORS
22.1 Requirements
22.1.1 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 16.7
above. Bolts used to replace rivets (or two-piece rivets) must be ASTM A-325. Washers, if used,
must be hardened steel.
22.1.2 It is permissible to replace discarded fasteners with bolts or two-piece rivets specified by
the car owner. The car owner or owner’s authorized agent must comply with the following:
22.1.2.1 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 connec-
tion 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.
22.1.2.2 The shear strength of the connection must be equal to the shear strength of the connec-
tion it replaced. Refer to Chapter 5, paragraph 5.2, for design and installation criteria of allowable
fasteners. (Do not recalculate Su).
22.1.2.3 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.
22.1.2.4 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.
10/2007 C-III [M-1002] 381

APPENDIX R M-1002
23.0 REPAIRS TO FIRE-DAMAGED TANK CAR TANKS

23.1 Requirements
23.1.1 Parts or portions of a tank car tank that have been exposed to fire or heat sufficient to ren-
der their performance unsafe must be replaced.
23.1.2 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, insula-
tion, gasket materials, surface oxidation film, etc.
23.1.3 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.
23.1.4 All valves and fittings must be removed, overhauled, and tested according to the valve
manufacturers’ instructions for suspected overheating.
24.0 REPAIRS TO TAPPED HOLES
24.1 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:
24.1.1 Insert installation is to be in accord with manufacturer’s specifications.
24.1.2 Insert material is to be compatible with commodity service.
24.1.3 After drilling out damaged threads, the metal surface is to be free of defects before retap-
ping for the insert.
24.1.4 Nominal thread size of the insert is to match the original size of the existing tapped hole.
Oversized holes are not permitted.
24.1.5 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:
24.1.5.1 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 mate-
rial, multiplied by the stress area (i.e., the area corresponding to the minor diameter) of
the stud/bolt.
24.1.5.2 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 = 0.4π DtSy 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 manufacturer’s specifications for
use, or using a calibrated torque wrench.
C-III [M-1002] 382 10/2007

M-1002 APPENDIX R
25.0 ADDITIONAL WELDING TO TANK CAR TANKS AFTER INITIAL HYDROTEST

25.1 Minor Welding to Tank Car Tanks Under Construction
When additional welding is found necessary following unit postweld heat treatment, the following
applies for tank car tanks fabricated from Table M10.1 material. (Note: hydrostatic testing may be
used in addition to NDT methods but not in place of NDT; see paragraph 21.0.)
Table R3. Processing repairs to tanks under construction
Welding Radiograph/
Purpose Code Ultrasonic PWHT
A No Yes
B Yes Yes
Pressure Cars C No Yes
D No Yes
E No Yes
A No Yes
B Yes Yes
Nonpressure Cars C No No
D No No
E No Yes
F No Yes
G No Yes
All Cars H No Yes
I Yes Yes
J No No
10/2007 C-III [M-1002] 383

APPENDIX R M-1002
25.1.1 Welding Purpose Code
Code Description
A Repair defective areas (after preparation for welding) equal to or less than 3/8 in.
(9.52 mm) wide and 3/16 in. (4.76 mm) deep, any length, if multiple repairs are
separated by unwelded plate.
B Repair defective areas (after preparation for welding) greater than 3/8 in. (9.52 mm)
wide or 3/16 in. (4.76 mm) deep, of any length.
C Repair surface imperfections whose defective area (after preparation for welding) does
not exceed 3/16 in. (4.76 mm) in depth, length of completed weld does not exceed 6 in.
(152 mm), and whose welds are separated by at least six times the material thickness.
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 pads to tank by welding.
G Add brackets to tank by welding.
H Lap-welded closure plates, 24 in. (610 mm) in perimeter, or less, added to the tank.
I Butt-welded insert plates, 24 in. (610 mm) in perimeter, or less, added to the tank.
J Add attachments to bottom outlet saddles, sumps, nozzle necks, and nozzle flanges by
welding.
25.1.2 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:
25.1.2.1 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.
25.1.2.2 During the heating and cooling periods, there shall be no greater variation in tempera-
ture than 250 °F (139 °C) throughout the heated area of the tank, nor shall any portion exceed
1250 °F (677 °C).
25.1.2.3 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).
25.1.2.4 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 (7055 °C divided by tank thickness in millimeters), but in
no case more than 500 °F (278 °C) per hour. Below 800 °F (427 °C), the tank may be cooled in still
air.
C-III [M-1002] 384 10/2007

M-1002 APPENDIX R
60°
Fig. R5 Welding fractures
45°
INSIDE OF TANK
Fig. R6 Welding rivet holes
60°
JOINT SEPARATION
Fig. R7 Welding fracture that extends into riveted joint
60°
JOINT SEPARATION
BACK-UP STRIP
Fig. R8 Welding fracture that extends into riveted joint (with back-up strip)
10/2007 C-III [M-1002] 385
APPENDIX R M-1002
Fig. R9 Insert application in void area on compartment car
C-III [M-1002] 386 10/2007

M-1002 APPENDIX R
t ACTUAL
3
" (2.38) MAX GAP
32
NOTE: MINIMUM FILLET OR GROOVE WELD SIZE ¼" (6.35 mm)

Fig. R10 Insert-type nozzle application (reference paragraph 15.5.4, this appendix)
10/2007 C-III [M-1002] 387

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

SET BY TANK SPECIFICATION.
Fig. R11 Lap joint nozzle application (reference paragraph 15.5.5, this appendix)
C-III [M-1002] 388 10/2007

M-1002 APPENDIX R
Fig. R12 Repair by weld overlay
10/2007 C-III [M-1002] 389

APPENDIX R M-1002
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., “C2—3-in. crack in weld”)
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
25. Disposition of Car: ____________________________________________________________________
Inspected by: ____________________________________ Title: __________________________________
rev 12/00
Fig. R13 Form SS-1 Report of Tank Car Stub Sill Inspection
C-III [M-1002] 390 10/2007
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 car’s 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 6.0, 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.

10/2007 C-III [M-1002] 391
APPENDIX R M-1002
C-III [M-1002] 392 10/2007

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

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–394
1.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–394
2.0 Operating Platforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–394
2.1 Side Operating Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–394
2.2 Top Operating Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–394
3.0 Ladders and Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–395
3.1 Ladders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–395
3.2 Top Operating Platform Railing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–395
3.3 End Platform Safety Railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–396
4.0 Handholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–396
4.1 Side Operating Platform Handholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–396
4.2 Dome Handholds for Cars Having Side Operating Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–396
5.0 Pertinent Portions of AAR Interchange Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–396
5.1 Field Manual of the AAR Interchange Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–396
10/2007 C-III [M-1002] 393

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.
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 fit-
tings 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 lad-
ders, 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] 394 10/2007

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 plat-
form—one, on platform side.
b. On car with continuous running board and top operating plat-
form—two, one on each side.
c. On car with top running boards and top operating platform—two,
one at each end.
d. On car with side running boards above tank center line—four,
one at each end of each running board.
e. On car with top operating platform, but without running
boards—two, 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); 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 boards—the 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 line—securely 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.
10/2007 C-III [M-1002] 395

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 appurte-
nances.
C-III [M-1002] 396 10/2007

M-1002 APPENDIX T
APPENDIX T
NONDESTRUCTIVE EXAMINATION
CONTENTS

1.0 General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–400
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–400
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–400
1.4 Levels of Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–402
1.5 Written Practice for Qualifying and Certifying NDT Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–402
1.6 Education, Training, and Experience Requirements for Initial Certification . . . . . . . . . . . . . . . . . . C-III–403
1.7 Training Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–403
1.8 Examination Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–404
1.9 Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–407
1.10 Technical Performance Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–407
1.11 Expiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–408
1.12 Interrupted Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–408
1.13 Recertification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–408
1.14 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–408
1.15 Revocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–408
1.16 Reinstatement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–408
1.17 Limited Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–409
1.18 NDT Procedure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–410
1.19 Qualification of NDT Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–410
1.20 NDT Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
1.21 NDT Inspection Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
1.22 Equipment Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
2.0 Acoustic Emissions Testing (AE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
2.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
2.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
2.3 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
2.4 Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
2.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
2.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
2.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–411
10/2007 C-III [M-1002] 397

APPENDIX T M-1002
3.0 Leak Testing (LT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–412

3.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–412
3.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–412
3.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–413
3.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–413
3.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–413
4.0 Liquid Penetrant Testing (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–414
4.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–414
4.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–414
4.4 Examinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–414
4.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–415
4.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–415
4.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–415
5.0 Magnetic Particle Testing (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–415
5.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–415
5.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–415
5.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–416
5.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–417
5.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–417
6.0 Radiographic Examination (RT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–417
6.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–417
6.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–418
6.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–421
6.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–423
6.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–423
7.0 Ultrasonic Testing (UT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–423
7.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–423
7.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–423
7.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–424
7.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–425
7.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–425
C-III [M-1002] 398 10/2007

M-1002 APPENDIX T
8.0 Ultrasonic Thickness Testing (UTT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–425

8.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–425
8.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–425
8.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–426
8.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–426
8.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–426
9.0 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–426
9.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–426
9.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–426
9.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–427
9.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–427
9.7 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–427
10.0 Thermal/Infrared (IR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–427
10.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–427
10.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–427
10.5 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–427
10.6 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–428
10.7 Record Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–428
10/2007 C-III [M-1002] 399

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 specifi-
cation, in a tank specification, or by other referencing documents. The most commonly used nonde-
structive testing methods are listed in Table T2. 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, Non-
destructive Testing and/or ASME Section V may be used to develop nondestructive test proce-
dures.
1.3 Definitions
Table T1. General definitions (page 1 of 2)
Certificate The document issued to the technician on successful completion of the
requirements for certification.
Certification Written testimony of qualification. The act of determining, verifying, and
attesting in writing to the qualification of personnel in conformance to
specified requirements.
Certifying The employer of the person being certified.
authority
Documented The condition of being in written or electronic form.
Employer The corporate, private, or public entity that employs personnel for wages,
salary, fees, or other considerations.
Evaluation A determination of the significance of a relevant indication.
Experience Work activities accomplished in a specific NDT method under the
direction of qualified supervision, including the performance of the NDT
method and reports, but not including time spent in organized training.
General A written examination addressing the basic principles of the applicable
examination NDT method.
Interpretation (of The determination of the relevance of indications.
NDT test data)
Method One of the disciplines of NDT (e.g., ultrasonic testing) within which
many techniques may be included.
NDT Level III An individual certified by the company as qualified to administer the
NDT program. 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 paragraph 1.8.4 can be certified as
an NDT Level III.
C-III [M-1002] 400 10/2007

M-1002 APPENDIX T
Table T1. General definitions (page 2 of 2)

Nondestructive A process that involves the inspection, testing, or evaluation of
testing (NDT) materials, components, and assemblies for materials’ discontinuities,
properties, and machine problems without further impairing or
destroying the parts serviceability. Throughout this appendix the term
NDT applies equally to the NDT inspection methods used for material
inspection and flaw detection.
Outside agency A company or individual who provides NDT services and whose
qualifications to provide these services have been reviewed and approved
by the employer contracting the company or individual.
Practical An examination used to demonstrate an individual’s ability in
examination conducting the NDT 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.
Procedure A detailed, written instruction for conducting nondestructive testing.
Procedures shall be approved by an NDT Level III certified in the
applicable method.
Qualification The education, skills, training, knowledge, and experience required for
personnel to properly perform to a specified NDT level.
Specific A written examination to determine an individual’s understanding of
examination procedures, codes, standards, specifications, and equipment or
instrumentation for an NDT method used by the employer.
Technique A specified process within an NDT method, for example magnetic
particle ‘yoke technique.’
Training An organized program developed to impart the knowledge and skills
necessary for qualification.
Verb usage As used in this standard, the word
• shall denotes a requirement;
• should denotes a guideline; and
• may denotes a choice.
Written practice A document prepared by the employer to specify methods, requirements,
examination, records, certifying official, etc., for a company’s NDT
personnel certification program.
10/2007 C-III [M-1002] 401

APPENDIX T M-1002
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 gen-
eral 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 inspec-
tion. 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 limita-
tions of the method to which certified. The Level II shall be capable of directing the work of train-
ees and Level I personnel and shall be able to organize and report nondestructive testing results.
1.4.3 Level I: A Level I shall have the skills and knowledge to properly perform specific calibra-
tions and tests, and with a prior written approval of the NDT Level III, to perform specific inter-
pretations 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. Train-
ees 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 administra-
tion 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
C-III [M-1002] 402 10/2007

M-1002 APPENDIX T
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 qual-
ification 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 company’s written practice.
1.6.3 To be considered for certification, the NDT Level III candidate must satisfy one of the fol-
lowing criteria:
1.6.3.1 A graduate from a minimum four-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 two 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 four years of experience beyond the Level II requirements in the applicable NDT
method(s).
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 per-
sonnel 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 candidate’s 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 employer’s written practice and this standard,
and so documented.
10/2007 C-III [M-1002] 403

APPENDIX T M-1002
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 particu-
lar applications to be performed. The sequence, content, amount of time spent, and depth of cover-
age 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 par-
ticular 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 com-
prehended.
1.7.7.2 Portions of recommended training topics contained in SNT-TC-1A 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 T4.
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. Admin-
istration 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 T2.
1.8.1.2 Specific: A specific written examination shall be approved by an NDT Level III. Adminis-
tration 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 examina-
tion shall address various examples of equipment, procedures, and test techniques that the candi-
date may use in the performance of assigned duties. The minimum number of questions required
for each method and level is listed in Table T3.
1.8.1.3 Practical: A practical examination shall be approved by an NDT Level III. Administra-
tion 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 appli-
cable nondestructive test method to examine at least one test sample for each technique to be used
in the candidate’s job and by documenting the results of the examination. At least 10 different
checkpoints requiring an understanding of the test variables and the employer’s procedural
requirements should be included in this practical examination.
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 vari-
ables and the employer’s procedural requirements should be included in this practical examina-
tion.
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M-1002 APPENDIX T
Table T2. 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
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
Table T3. 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
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
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APPENDIX T M-1002
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 employer’s 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 examina-
tion services meet the requirements of the employer’s written practice.
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 employer’s 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
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M-1002 APPENDIX T
1.8.4.3 Specific Examination (for each method)

• Twenty questions relating to specifications, equipment, techniques, and procedures appli-
cable to the employer’s product(s) and methods employed and to the administration of the
employer’s written practice.
The employer may delete the specific examination if the candidate has a valid ASNT Level III cer-
tificate 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.
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 rec-
ognized by the employer’s 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 employer’s 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 employer’s 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 employer’s
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 employer’s 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 employer’s 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 employer’s written practice, the technical performance of
Level I and II personnel should be evaluated and documented by an NDT Level III. The evaluation
and documentation should follow the format and guidelines described in the written procedure.
10/2007 C-III [M-1002] 407

APPENDIX T M-1002
1.11 Expiration
An individual’s 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.
1.12 Interrupted Service
1.12.1 The employer’s 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 recertifica-
tion 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 employer’s Level III
1.13.2 Maximum recertification intervals shall be as follows:
• Levels I and II—3 years
• Level III—5 years
1.14 Suspension
The employer shall suspend an individual’s certification under any of the following situations:
• The vision examination interval has been exceeded. Certification is reinstated concur-
rently with passing the vision reexamination.
• The individual’s performance is determined to be deficient in the required method or tech-
nique for specific documented reasons.
• An individual’s conduct is deemed by the employer to be or have been unethical or incompetent.
1.15 Revocation
1.15.1 The employee’s 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 pro-
vided all of the following conditions are met to the new employer’s 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 employee’s 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 experience than recommended in Table T4. The minimum
requirements for limited certification shall be described in the company’s written practice. Any
limitations or restrictions placed upon a qualified person shall be described on the certification.
Table T4. Minimum initial training and experience requirements
Examination Training Hours Experience Required
Technique Level
Method 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
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 RVIa/
II 16 3 / 210
I 8 40 hours
Thermal/Infrared
II 8 80 hours
a/ Must be VT-certified as a prerequisite for RVI certification.
NOTES:
1. TECHNIQUES:
• BT—BUBBLE TEST
• PCT—PRESSURE CHANGE TEST
• HDLT—HALOGEN DIODE LEAK TEST
• MSLT—MASS SPECTROMETER LEAK TEST
• CRLT—CHEMICAL REACTIVITY LEAK TEST
• RVI—REMOTE VISUAL INSPECTION
• UTT—ULTRASONIC THICKNESS TEST
• VT— VISUAL TESTING
• IR—THERMAL INFRARED
2. INITIAL EXPERIENCE MAY BE GAINED SIMULTANEOUSLY IN TWO OR MORE METHODS IF THE CANDIDATES SPEND A MINIMUM OF 25% OF WORK TIME ON EACH METHOD
FOR WHICH CERTIFICATION IS SOUGHT. THE REMAINDER OF THE WORK TIME CLAIMED AS EXPERIENCE IS SPENT IN NDT-RELATED ACTIVITIES AS DEFINED IN THE
EMPLOYERS WRITTEN PRACTICE.
3. FOR CERTIFICATION DIRECTLY TO LEVEL II WITH NO TIME AT LEVEL I, THE TRAINING AND EXPERIENCE HOURS SHALL BE THE SUM OF TIME REQUIRED FOR LEVEL I
AND LEVEL II.
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APPENDIX T M-1002
1.18 NDT Procedure Requirements

1.18.1 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 accor-
dance 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. In
addition to the method section, the procedure shall, as a minimum, contain the following:
• Personnel requirements
• Responsibility requirements
• Techniques on how inspection is to be performed
• Surface preparation requirements
• Calibration requirements
• Specific equipment requirements (type or model, if applicable)
• Temperature constraints
• Acceptance criteria
• Report and data requirements, including forms
• Post-examination cleaning requirements
• Procedure qualification requirements, including sensitivity and reliability
• Method and technique limitations and special requirements
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 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.
1.19.3 Demonstration
1.19.3.1 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.
1.19.3.2 The NDT Level III shall witness the demonstration of the procedure.
1.19.3.3 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 com-
pleted and shall describe the demonstration specimen and results.
1.19.3.4 The NDT procedure is considered qualified when the results of the demonstration indi-
cate the ability to detect discontinuities to the satisfaction of the NDT Level III. The NDT Level III
and the witness(es) shall sign the Procedure Qualification Record form.
1.19.3.5 All records of the demonstration shall be documented.
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M-1002 APPENDIX T
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 proce-
dure:
• Technique
• Specific equipment and materials used
• Equipment test settings, where applicable
• Surface preparation, if required
• Post-examination cleaning, if required
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 Man-
ual of Standards and Recommended Practices, Section J, Specification M-1003; and with the com-
pany’s 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.
10/2007 C-III [M-1002] 411

APPENDIX T M-1002
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 rates
• Acceptable test sensitivity or leakage rate
• Pressure, pressurizing medium, and percentage concentrations to be used
• Hold/soak and dwell time
• Leak detector fluid and percentage concentrations, if applicable
• Pressure gauge and temperature measuring device range
• Tracer gas(es) and percentage concentrations, if applicable
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 sur-
face 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 pro-
duced 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 bub-
bles on the surface.
3.4.3 Pressure Change Test (PCT)
3.4.3.1 Gauges used to monitor pressure change are to be compatible to the sensitivity require-
ments 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.
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M-1002 APPENDIX T
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 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 sul-
fide. 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 specifica-
tion.
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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APPENDIX T M-1002
4.0 LIQUID PENETRANT TESTING (PT)

4.1 Procedures
Written procedures shall include at least the following:
• Cleaning dry-time per paragraph 4.4.3.
• Type of penetrant material
• Penetrant dwell time and developer time
• Post-examination cleaning requirements
4.2 Personnel
4.3 Calibration
4.3.1 Equipment calibration shall be in accord with paragraph 1.22 above (Equipment Calibra-
tion).
4.3.2 Ultraviolet light intensity shall be measured with a calibrated ultraviolet light meter. A
minimum of 800 μW/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 evap-
oration 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
4.4.6 Fluorescent penetrant examinations shall be performed using an ultraviolet light. Fluores-
cent penetrant examination shall be performed in a darkened area. Personnel performing the fluo-
rescent 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. Photosensi-
tive glasses shall not be worn during the test by examiners using these penetrants (Note: direct
viewing of ultraviolet light should not take place).
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M-1002 APPENDIX T
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-remov-
able; 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:
• Magnetization techniques to be used
• Equipment to be used for magnetization
• Type of ferromagnetic particles to be used; manufacturer, color, wet or dry, etc.
• Magnetization currents (type and amperage)
• Demagnetization
• Directions, extent, and method of examination
• Method of applying examination media
5.2 Personnel
5.3 Calibration
tion).
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 mini-
mum at the maximum pole spacing allowed by the written procedure(s) to be used.
5.3.4 Ultraviolet light intensity shall be measured with a calibrated ultraviolet light meter. A
minimum of 800 μW/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 magnetiz-
ing field shall be verified using a magnetic field indicator as described and shown in ASME Section
V, Article 7, T-753.1 and Figure T-753.1.1.
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APPENDIX T M-1002
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 demon-
strated 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 dem-
onstrated 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 exam-
ined. 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 exam-
ined. 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. Fluores-
cent particle examination shall be performed in a darkened area. Personnel performing the fluo-
rescent 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 ultravi-
olet 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
tion.
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M-1002 APPENDIX T
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 mag-
netization 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:
• Material types and thickness ranges
• Isotope used or maximum X-ray voltage
• Minimum source-to-film distance
• Maximum source size
• Screens used
• Surface condition and preparation
• Detection of backscatter radiation
• System of identification of radiographs
• Density limitations and method(s) for monitoring density limitations and variations of
radiographs
• Image quality indicator (IQI) selection and placement
• Radiographic techniques (single-wall or double-wall)
• Radiation energy selection
• Radiograph quality
• IQI sensitivity requirements
• Film classification
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 pro-
duction 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.
6.1.2.4 Radiographic film shall be of industrial classification I, II, or III, as recommended in
ASTM E1815.
10/2007 C-III [M-1002] 417

APPENDIX T M-1002
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 differ-
ences prohibit it.
6.2 Personnel
6.3 Calibration
tion) and the following:
6.3.2 Acceptable source size verification may be made by documentation of the equipment manu-
facturer’s or supplier’s 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 suit-
able 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.
C-III [M-1002] 418 10/2007

M-1002 APPENDIX T
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 T5. 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 T7. 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 require-
ments. Wire sizes equivalent to corresponding 1T, 2T, and 4T holes for hole-type IQIs are listed in
Tables T5 and T6.
6.4.6.3 The essential wire size for wire IQIs shall be as specified in Table T7 A smaller or a thin-
ner wire IQI than listed for each range may be used, provided all other requirements for radiogra-
phy 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 T5. 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
10/2007 C-III [M-1002] 419

APPENDIX T M-1002
Table T6. Hole IQI Designation, Thickness, Hole Diameters and Corresponding Wire IQI Size (SI Units)
IQI
Hole IQI Thick- 1T Hole Wire Size 2T Hole Wire Size 4T Hole Wire Size
Designa- ness Diameter 1T Diameter 2T Diameter 4T
tion (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 T7. 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 thru 3/8 0.012 12 4T 0.012
Over 3/8 thru 1/2 0.015 15 4T 0.016
Over 1/2 thru 5/8 0.015 15 4T 0.016
Over 5/8 thru 3/4 0.017 17 4T 0.020
Over 3/4 thru 7/8 0.020 20 4T 0.025
Over 7/8 thru 1 0.020 20 4T 0.025
Over 1 thru 1 1/4 0.025 25 4T 0.032
Over 1 1/4 thru 1 1/2 0.030 30 2T 0.025
Over 1 1/2 thru 2 0.035 35 2T 0.032
Over 2 thru 2 1/2 0.040 40 2T 0.040
Over 2 1/2 thru 3 0.045 45 2T 0.045
C-III [M-1002] 420 10/2007

M-1002 APPENDIX T
Table T8. IQI Selection (SI Units)

Nominal Material Essential
Thickness of IQI Essential
Thickness Range Wire Size
IQI (mm) Designation Hole Size
(mm) (mm)
Up to 6.35 inclusive 0.254 10 4T 0.25
Over 6.35 thru 9.52 0.318 12 4T 0.28
Over 9.52 thru 12.7 0.381 15 4T 0.41
Over 12.7 thru 15.9 0.381 15 4T 0.41
Over 15.9 thru 19.0 0.444 17 4T 0.51
Over 19.0 thru 22.2 0.508 20 4T 0.63
Over 22.2 thru 25.4 0.508 20 4T 0.63
Over 25.4 thru 31.8 0.635 25 4T 0.81
Over 31.8 thru 38.1 0.762 30 2T 0.63
Over 38.1 thru 50.8 0.889 35 2T 0.81
Over 50.8 thru 63.5 1.016 40 2T 1.02
Over 63.5 thru 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 fabricator’s 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 interpre-
tation of the resultant images.
10/2007 C-III [M-1002] 421

APPENDIX T M-1002
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 differ-
ence 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% den-
sity 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, interpre-
tation 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 inter-
est in the radiograph. Room illumination must be arranged such that there are no reflections from
the surface of the film under examination.
C-III [M-1002] 422 10/2007

M-1002 APPENDIX T
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 manufacturer’s 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
• Weld and/or material types and configurations to be examined, including dimensions and
product form (casting, forging, plate, etc.)
• The surface or surfaces from which the examination shall be performed
• 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
• Directions, extent, and method of scanning
• Data to be recorded and method of recording (manual or mechanized)
• Recording equipment, as applicable
• Rotating, revolving, or scanning mechanisms
• Calibration procedure
7.2 Personnel
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 malfunc-
tioning 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 5.
10/2007 C-III [M-1002] 423

APPENDIX T M-1002
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 5, for the applicable material product form and the provi-
sions 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 scan-
ning speed.
7.4.4 Examinations shall be conducted with a pulse-echo ultrasonic instrument capable of gener-
ating 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 exami-
nation 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 sys-
tem should compensate for the effective change in search unit transmitting area between the ref-
erence 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.
7.5 Evaluation
7.5.1 All examinations shall be evaluated in terms of acceptance standards of the referencing
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.
C-III [M-1002] 424 10/2007

M-1002 APPENDIX T
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
• Weld and/or material types and configurations to be examined, including dimensions and
product form (casting, forging, plate, etc.)
• The surface or surfaces from which the examination shall be performed
• Calibration procedure
• Search unit type, frequency(ies), and transducer size(s)
• Special transducer attachments
• Directions, extent, and method of scanning
• Data to be recorded and method of recording (manual or mechanized)
• Recording equipment, as applicable
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.
8.3 Calibration
tion) and the following:
8.3.2 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 malfunc-
tioning 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.
10/2007 C-III [M-1002] 425

APPENDIX T M-1002
8.3.3 The examination system shall be calibrated on at least three calibration thicknesses cover-
ing 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 thick-
ness, 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
tion.
8.6 Reports
Ultrasonic thickness 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
8.7 Records
9.0 VISUAL INSPECTION
9.1 Procedures
• Illumination requirements and special illumination instruments or equipment to be used
9.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above.
9.3 Calibration
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M-1002 APPENDIX T
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 sur-
face 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 examina-
tion 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
tion.
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
10.0 THERMAL/INFRARED (IR)
10.1 Procedures
• Emissivity requirements of the test surface
• Method of obtaining temperature differential (inside of tank to outside of jacket)
• Amount of temperature differential required
• Scanning technique
• Environmental conditions (weather, sunshine, shop 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
tion.
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APPENDIX T M-1002
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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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.
The NDT Level III and a minimum of one other qualified individual shall witness the demon-
stration of the procedure.
Results of the procedure demonstration shall be documented using an NDT Procedure Qualifica-
tion Record having spaces to record the procedure identification, signatures, and date. In addi-
tion, 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
10/2007 C-III [M-1002] 429

APPENDIX T M-1002
C-III [M-1002] 430 10/2007

M-1002 APPENDIX U
APPENDIX U
MAINTENANCE PROGRAM DEVELOPMENT
Recommended Practice
RP-263
CONTENTS

1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–432
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–432
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–432
1.4 Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–433
1.5 Use of Contract Tank Car Facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–434
2.0 Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–435
2.1 Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–435
2.2 Sample Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–436
2.3 Supplemental Maintenance or Modification Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–436
3.0 Reports and Service Reliability Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–437
3.1 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–437
3.2 Service Reliability Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–437
3.3 Program and Interval Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–438
10/2007 C-III [M-1002] 431

APPENDIX U M-1002
APPENDIX U
MAINTENANCE PROGRAM DEVELOPMENT
Recommended Practice
RP-263
Adopted: 2003
1.0 GENERAL
1.1 Introduction
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 be-
tween what might fail, how it might fail, and when it might fail for the tank and associated equip-
ment (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 fur-
ther 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 pro-
gram for tank cars. This appendix covers the application and coordination of regulatory and indus-
try 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 mainte-
nance program and schedule. (See paragraph 1.4 for responsibilities).
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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1.3 Definitions
The following definitions apply:
Table U1. General definitions
Accidental damage (AD) A physical defect of an item caused by contact with an object
during the manufacture, maintenance, or operation of the
tank.
Environmental damage (ED) Corrosion, erosion, or other physical deterioration of an
item’s strength or resistance to failure because of chemical
interaction with its climate or environment.
Fatigue damage (FD) The initiation and subsequent propagation of a crack or
cracks due to cyclic loading.
Fitness-for-service The tank car conforms to federal regulations, industry stan-
dards, and the owner’s acceptance criteria, and is otherwise
suitable for continued service.
Initiator A company or organization that is responsible for identifying
and reporting inspection results and failures of a material or
service.
Lining or coating owner The party responsible for the maintenance for the lining or
coating.
Maintenance program The owner or manufacturer’s procedures to maintain fit-
ness-for-service.
Operator/user A facility that loads or unloads a tank and then offers the car
for transportation.
Service equipment owner The party responsible for the maintenance of the service
equipment.
Service reliability assessment A systematic evaluation of an item based on an analysis of
collected information from in-service experience to verify an
item's resistance to failure and deterioration.
Tank car owner The company that holds the registration for the reporting
mark stenciled on the side of the car.
1.4 Responsibilities
1.4.1 The tank car owner is responsible for ensuring the fitness-for-service of the tank car. A tank
car owner may contract with another person to perform one or more of its maintenance functions.
At a minimum, each tank car owner is responsible for the following:
1.4.1.1 The development or adoption of a maintenance program for each tank car or design of
tank cars.
1.4.1.2 The collection and analysis of maintenance data to ensure fitness-for-service of each tank
car.
1.4.1.3 The performance of maintenance, repairs, alterations, conversions, and reporting in
accord with its maintenance, qualification, and repair procedures.
1.4.1.4 Ensuring that each tank car facility used for maintaining its tank car has a current AAR
certification or registration as appropriate to the work being performed.
1.4.1.5 Ensuring that each of its company-owned tank car facilities has a copy of its maintenance
manual and detailed work instructions to complete each task.
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1.4.1.6 Ensuring, on a continuing basis, the performance and effectiveness of its maintenance
program and all work instructions to complete each task.
1.4.2 Each operator/user of a tank car (i.e., loading and unloading facilities) is responsible for the
following:
1.4.2.1 Reporting to the owner all observed damage, deterioration, failed components, and non-
compliant parts, whether repaired or not.
1.4.2.2 Obtaining the car owner’s permission and owner-approved instructions before undertak-
ing maintenance, modifications, or repairs.
1.4.2.3 Reporting to the owner the content of work performed under paragraph 1.4.2.2 when com-
pleted.
1.4.2.4 Ensuring that whatever work the operator/user authorizes to be done on a tank car is per-
formed by facilities that possess appropriate and current AAR certification or registration.
1.4.3 Each manufacturer of a tank car is responsible for the following:
1.4.3.1 Working with car owners to resolve design-related or manufacturing-related failure prob-
lems identified by owners, operator/users, or maintenance facilities.
1.4.3.2 Working with car owners on request to define and document maintenance requirements
for new cars or designs of new cars.
1.4.3.3 Providing the component supplier manuals, upon request, for all new cars or designs of
new cars.
1.4.3.4 Providing the maintenance requirements for fatigue-critical locations, on request, for all
existing cars or designs of cars.
1.4.4 Each tank car facility is responsible for the following
1.4.4.1 Undertaking maintenance, repair, or other work only with the car owner’s permission and
using only procedures approved by the car owner, along with any other documents to which these
procedures refer.
1.4.4.2 Reporting all damage, deterioration, failed components, and noncompliant parts to the
owner, whether repaired or not.
1.4.4.3 Ensuring that it has and maintains an AAR certification or registration as appropriate to
the work being performed.
1.5 Use of Contract Tank Car Facilities
1.5.1 A tank car owner may use a contract tank car facility for the performance of activities in
accordance with this appendix. However, this does not relieve the tank car owner from its respon-
sibility to ensure the fitness-for-service of the tank car in accord with this appendix. A tank car
owner may use a contract tank car facility provided the following conditions are met:
1.5.1.1 The contract tank car facility shall have a current AAR certification or registration as
appropriate to the work being performed.
1.5.1.2 The tank car owner shall provide each contract tank car facility it approves with a current
copy of the owner’s maintenance manual, the maintenance plan, or a portion thereof. Otherwise,
the owner shall approve the contractor’s maintenance program.
1.5.1.3 The tank car owner shall have a system in place that ensures the accuracy, completeness,
format, and transmission of the contract tank car facility’s data back to the car owner’s mainte-
nance program.
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M-1002 APPENDIX U
1.5.2 Unless authorized by the tank car owner, contract facilities shall treat the owner’s plans,
procedures, manuals, and data as confidential and proprietary information.
2.0 MAINTENANCE PLAN
2.1 Maintenance Manual
2.1.1 The maintenance manual provides maintenance instructions and consists of at least the fol-
lowing 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 inspec-
tion.
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 manufacturer’s 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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2.2 Sample Maintenance Plan
Table U2. 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 (devia-
tion 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 main-
tenance 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 AAR’s Executive Direc-
tor—Tank 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 com-
ponent 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 AAR Form 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 manufactur-
ing 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 R-1 report (See MSRP Specifica-
tion M-1002, Appendix R, paragraph 4.3) 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 owner’s 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 sam-
pling, 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 rep-
resenting 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 dis-
plays, summarizing the period’s 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 mainte-
nance interval or content if the systematic evaluation shows that an owner’s 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, reliabil-
ity, 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 docu-
mentary 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 fed-
eral 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 owner’s engineering analysis, maintenance data, pooled industry data, historical data, bene-
fit/cost data, and testing.
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M-1002 APPENDIX U
PRESSURE RELIEF VALVE INSPECTION REPORT

(REQUESTED BY AAR 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. No test TESTING
10. Is flow passageway 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. Perform the following tests. 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
16. Start to discharge test 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ______________ psig TESTING
18. Start to discharge test 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ______________ psig
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ______________ in.
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 and conditions: ________________________________________________
29. Comments ________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
30. Reporting facility _____________________________________ __________________________________
(Station Stencil) (Phone Number)
Date Tester Name (print) ID#
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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 1988—03 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 nee-
dle 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 commod-
ity). 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 pres-
sure 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 valve’s 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 hear-
ing.”
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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 de-
fined as “The pressure, measured at the valve inlet after closing, at which no further flow is de-
tected 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 manufacturer’s 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 condition—The plating is intact and in good condition (less than 1 in.2 gone).
B. Some corrosion—The plating is no longer intact and some corrosion exists.
C. All corrosion—The plating no longer exists and the entire spring is covered with corrosion.
D. Cracked—The 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 num-
ber in line 29.
A. Good condition—The spring has no corrosion or pitting and is in good condition.
B. Some corrosion—Some corrosion or pitting exists.
C. All corrosion—The entire spring is covered with corrosion or pitting.
D. Cracked—The 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.
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. Good—The stem is straight. The threads and the seat area are in good condition.
B. Dirty—The seat seal area has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean-up.
C. Cracked—The stem has visible cracks.
D. Bent—The stem is bowed or bent when rolled on a flat surface.
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APPENDIX U M-1002
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/clean—The seat seal area is bright and clean (like new).
B. Dirty—The seat seal area has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean up.
C. Corroded—The seat seal area has pitting that would not allow the PRV to be rebuilt.
D. Gouged—The 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 con-
ditions exist, note the condition and line number in line 29.
A. Like new—The O-ring is still clean, soft, and pliable and seals properly in the PRV.
B. Dirty—The O-ring has contamination on it, which may not allow it to function properly.
C. Cracked—The O-ring is no longer soft and pliable. It is hard and cracks if flexed.
D. Swelled—The O-ring is swollen and over-sized for the seat area in the PRV.
E. Metal-to-Metal—The 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 new—The O-ring is still clean, soft, and pliable and seals properly in the PRV.
B. Dirty—The O-ring has contamination on it, which may not allow it to function properly.
C. Cracked—The O-ring is no longer soft and pliable. It is hard and cracks if flexed.
D. Swelled—The O-ring is swollen and over-sized for the seat area in the PRV.
E. Metal-to-Metal—The valve design does not have an O-ring, but a metal-to-metal seat.
27. Inspect the seal retainer and circle the choice that best describes the condition of it. If other con-
ditions exist, note the condition and line number in line 29.
A. Bright/clean—The seal retainer is bright and clean (like new).
B. Dirty—The seal retainer has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean-up.
C. Corroded—The seal retainer has pitting that would not allow the PRV to be rebuilt.
D. Gouged—The 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 manufacturer’s mark-
ings 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 tear-
down of the PRV.
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M-1002 APPENDIX U
30. Record the following information for the facility that removed the valve from the car and per-
formed 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.
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M-1002 APPENDIX W
APPENDIX W
WELDING OF TANK CAR TANKS
CONTENTS

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–448
1.2 Certified Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–448
1.3 Repairs, Alterations and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–448
1.4 Welding Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–448
3.0 Requirements for Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–451
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–451
3.2 Tank Shell Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–451
3.3 Welds Other than Tank Shell Joints—Attachments Welded Directly to the Tank Shell. . . . . . . . . . C-III–451
4.0 Test Plate Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–452
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–452
4.2 Longitudinal Joint Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–452
4.3 Circumferential Joint Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–452
4.4 Straightening of Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–452
4.5 Heat Treatment of Test Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–452
4.6 Radiography of Test Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–452
4.7 Test Specimens Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–453
5.0 Types and Purposes of Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–453
5.1 Tension, Bend, and Fillet Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–453
5.2 Impact Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–453
5.3 Radiographic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–453
5.4 Corrosion Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–453
5.5 Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–453
6.0 Tension Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–454
6.1 Joint Tension Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–454
6.2 All-Weld-Metal Tension Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–454
6.3 Joint-Tension Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–454
6.4 All-Weld-Metal Tension Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–454
7.0 Bend Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–455
7.1 Guided-Bend Test Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–455
7.2 Guided-Bend Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–455
8.0 Fillet Weld Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–455
8.1 Fillet Weld (Tee-Joint) Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–455
8.2 Fillet Weld Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–455
9.0 Impact, Corrosion and Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–456
10/2007 C-III [M-1002] 445

APPENDIX W M-1002

9.1 Impact Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–456
9.2 Corrosion Specimens and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–457
9.3 Hardness Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–458
10.0 Procedure and Performance Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–458
10.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–458
10.2 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–458
10.3 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–459
10.4 Identification of Welds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–459
10.5 Qualification Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–459
10.6 Weld Orientation and Test Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–459
11.0 Nondestructive Examinations and Acceptance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–460
11.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–460
11.2 Radioscopic Acceptance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–461
11.3 Liquid Penetrant Examination Acceptance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–463
11.4 Magnetic Particle Examination Acceptance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–463
11.5 Ultrasonic Examination Acceptance Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–464
12.0 Performance Qualification of Welders and Welding Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–465
12.1 Qualification of Welders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–465
12.2 Qualification of Welding Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–465
12.3 Weldments Involving Combination of Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–465
12.4 Essential Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–466
12.5 Test Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–466
12.7 Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–468
12.8 Renewal of Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–468
13.0 Procedure Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–468
13.1 Qualification of Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–468
13.3 Test Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–472
13.5 Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–474
13.6 Renewal of Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–474
13.7 Weld Buildup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–474
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M-1002 APPENDIX W

14.0 Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–475
14.1 Forming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–475
14.2 Cutting to Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–475
14.3 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–475
14.4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–476
14.5 Welding Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–476
14.6 Out-of-Roundness of Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–476
14.7 Tolerance for Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–476
14.8 Arc Strikes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–476
15.0 Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–476
15.1 Cleaning During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–476
15.2 Groove Preparation for Back Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–476
15.3 Alignment Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–477
15.4 Weld Reinforcement (Butt Welds). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–477
15.5 Fillet Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–477
15.6 Interrupted Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–477
15.7 Identification of Welds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–478
15.8 Repair of Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–478
15.9 Surface Quality of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–478
15.10 Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–478
15.11 Low Hydrogen Electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–479
16.0 Welding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–479
16.1 Welding Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–479
17.0 Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–483
17.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–483
17.2 Procedures for Postweld Heat Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–484
17.3 Requirements for Postweld Heat Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–484
17.4 Carbon Steel Tanks (Material Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–484
17.5 Manganese-Molybdenum Steel Tanks (Material Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–485
17.6 Manganese-Silicon Steel Tanks (Material Group 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–485
17.7 Nonferrous Metal Tanks (Material Groups 2, 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–485
17.8 Nickel Alloy Steel Tanks (Material Group 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–485
17.9 High Alloy Steel Tanks (Material Group 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–486
18.0 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–486
18.1 Quality Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–486
19.0 Radiographic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–486
19.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–486
19.2 Weld Joints to be Radiographed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–486
19.3 Radiography of Nonpressure Tanks Constructed in Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–487
10/2007 C-III [M-1002] 447

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 car tanks. Other welding on
tank cars, 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 fab-
rication 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. W22).
2.0 DEFINITIONS
In addition to definitions and abbreviations in DOT 179.2, the following definitions apply in this
appendix. Where not defined herein, the definitions contained in AWS Standard A3.0 apply.
Table W1. General definitions (page 1 of 3)

Butt weld A weld in a joint between two members lying approximately in the
same plane. It may be either single- or double-welded.
Certified The AAR Tank Car Committee has issued written authorization
for a facility to fabricate, alter, convert, or perform welded repairs
on tanks. See Appendix B.
Company A facility or group of facilities under common ownership that uti-
lize the same program of welding standards and documentation.
Double-welded butt A butt joint welded from both sides.
joint
Essential variables Those welding parameters considered critical, for which a change
outside of a given range requires a new qualification test.
Extension As applied to tank cars, a static or mobile extremity capable of
making limited repairs supported and controlled by an AAR-certi-
fied facility.
Fabricate (fabrication) The construction of a tank car tank consisting of a shell and heads
with connections welded directly thereto, with or without stub sill
and body bolster components.
Fillet weld A weld of approximately triangular cross section joining two sur-
faces approximately at right angles to each other, in a lap, tee, or
corner joint.
Fluoroscope A phosphor screen, X-ray image intensifier, or other fluorescent
medium that emits visible light in direct proportion to the amount
and distribution of radiation impinging on its input surface.
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M-1002 APPENDIX W

Fluorotape A tape recording of an image from the output of a fluoroscope. The
image is recorded on video magnetic tape for playback on a suit-
able television receiver.
Forge welding A welding process wherein coalescence is produced by heating in a
forge or other furnace and by applying pressure or blows.
Full fillet weld A fillet weld whose size is equal to the thickness of the thinner
member being joined.
Fusion Welding Any welding process that uses fusion of the base metal to make
the weld.
Groove weld A weld made in the groove between two members to be joined.
Heat treatment Heating and cooling a metal or alloy in such a way as to obtain
desired conditions or properties. Heating for the sole purpose of
hot working is excluded from the meaning of this definition.
Image quality indicator A device whose image in a radiograph is used to determine radio-
(IQI) graphic quality level.
Inspector A person authorized by the tank owner or, when not authorized by
the owner, designated by the tank fabricator or car builder, to per-
form inspection.
Lap joint A joint between two overlapping members in parallel planes.
Nondestructive testing Test methods that do not damage or otherwise affect the perfor-
mance of the item being tested. Typical nondestructive test meth-
ods are visual, radioscopic, liquid penetrant, magnetic particle,
ultrasonic, and acoustic emission. All test methods have unique
limitations and therefore must be carefully selected and used to
achieve the desired results.
Acoustic emission inspection: A nondestructive test method,
utilizing sounds emitted by materials when under stress, to detect
internal or surface discontinuities.
Liquid penetrant inspection: A nondestructive test method
utilizing contrasting liquids/dyes that penetrate to highlight dis-
continuities open to the surface (cracks, porosity, seams, etc.).
Magnetic particle inspection: A nondestructive test method
utilizing variations in magnetic fields to detect discontinuities at
or slightly below the surface. Limited to ferromagnetic materials.
Radioscopy: A nondestructive test method of observing the inter-
nal characteristics of objects that are opaque to light with X-rays
or gamma rays, specifically with radiographic or fluoroscopic tech-
niques.
Ultrasonic inspection: A nondestructive test method that trans-
mits ultrasonic energy through the test material to detect internal
and surface discontinuities. Used also for thickness measure-
ments.
Visual inspection: A nondestructive test method utilizing vision
to detect surface imperfections in materials (including welds).
Plug weld A weld made in a circular hole in one member of a joint, fusing
that member to another member. A fillet welded hole is not to be
construed as conforming to this definition.
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APPENDIX W M-1002

Postweld heat Any heat treatment subsequent to welding.
treatment
Procedure qualification A document providing the actual welding variables used to pro-
record (PQR) duce an acceptable procedure qualification test weld and the
results of tests conducted on the weld.
Qualified Means that the welder, welding operator. or welding procedure
qualification requirements of this appendix have been met.
Radiograph The film transparency or paper image obtained by development of
a sensitized emulsion film after passage of radiation (X-rays or
gamma rays) through an object to expose the emulsion.
Radiotape A film or paper radiograph or fluorotape.
Single-welded butt joint A butt weld with filler metal added from one side only.
Size (fillet) For equal leg fillet welds, the leg lengths of the largest isosceles
right triangle that can 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 another member. The hole may be open at one
end. A fillet-welded slot is not to be construed as conforming to
this definition.
Stress relief heat Uniform heating of a structure or a portion thereof to a sufficient
treatment temperature to relieve the major portion of the residual stresses,
followed by uniform cooling.
Throat (fillet) Theoretical throat. The distance from the beginning of the joint
root perpendicular to the hypotenuse of the largest right triangle
that can be inscribed within the cross-section of a fillet weld.
Welder One who performs manual or semiautomatic welding.
Welding operator One who operates adaptive control, automatic, mechanized, or
robotic welding equipment.
Welding procedure A document providing in detail the required variables for specific
specification (WPS) application to ensure repeatability by properly trained welders
and welding operators.
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M-1002 APPENDIX W
3.0 REQUIREMENTS FOR NONDESTRUCTIVE EXAMINATION

3.1 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 para-
graphs.
3.2 Tank Shell Joints
3.2.1 For manual and semiautomatic welding procedures, the weld root pass and each layer of
multi-pass weld shall be visually examined to make sure they are free from cracks, overlap, incom-
plete 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.
3.2.2 All completed welded butt joints shall be visually inspected in accord with paragraph 15.9
below and radiographed in accord with paragraph 19.0, also below.
3.3 Welds Other than Tank Shell Joints—Attachments Welded Directly to the Tank
Shell
3.3.1 The root pass and each layer of multi-pass weld shall be visually examined to make sure
they are free from cracks, overlap, lack of fusion, and slag inclusions prior to deposition of subse-
quent weld passes. The welder making the weld is responsible for this, which shall be monitored
by the welding inspector.
3.3.2 All completed welds shall be visually inspected in accord with paragraph 15.9 below.
3.3.3 In addition to the requirements in paragraphs 3.3.1 and 3.3.2, pressure car tank and alumi-
num tank (pressure and nonpressure) completed fillet welds listed below shall be examined in
accord with paragraph 11.0 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 prac-
tical, 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 longitu-
dinal 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 lon-
gitudinal 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
3.3.4 Ultrasonic testing of welds may be employed in lieu of magnetic particle or liquid pene-
trant inspections. Ultrasonic testing of welds shall be performed in accord with the requirements
of paragraph 11.0 below.
10/2007 C-III [M-1002] 451

APPENDIX W M-1002
4.0 TEST PLATE REQUIREMENTS

4.1 General
4.1.1 Test plates shall be prepared, tested, and evaluated in accordance with applicable portions
of paragraphs 5.0, 6.0, 7.0, and 9.0 below.
4.1.2 A test plate shall be prepared during fabrication for each WPS used in fabrication of the tank shell.
4.1.3 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 fabricator’s inspector.
4.1.4 A test plate shall be prepared as a part of the qualification requirements for each welding
procedure. See paragraph 13.1.2 below.
4.1.5 When impact tests are required, the test plate groove details shall be the same as used for
the tank fabrication.
4.2 Longitudinal Joint Test Plates
4.2.1 For each tank having a longitudinal welded joint, a test plate shall be prepared from mate-
rial 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 fabrica-
tion 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.
4.2.2 The test plates may be attached to a shell plate being welded, reference Fig. W1A, so that
the weld metal shall be deposited in the test plate continuously with the weld metal deposited in
the longitudinal joint.
4.2.3 As an alternative, detached test plates may be prepared, but weld metal shall be deposited
using the same WPS used for the longitudinal joints.
4.3 Circumferential Joint Test Plates
4.3.1 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.
4.3.2 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.
4.4 Straightening of Test Plates
The test plate shall be supported so that distortion resulting from welding shall not throw the fin-
ished 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.
4.5 Heat Treatment of Test Plates
4.5.1 The test plate shall be subjected to the same postweld heat treatment procedure required in
paragraph 17.0 below for the related tank. At no time shall the test plate be heated to a tempera-
ture higher than that used for postweld heat treating the related tank.
4.5.2 When production test plate impact test specimens are required by DOT or AAR special com-
modity requirements, the test plate shall be postweld heat treated with its related tank.
4.6 Radiography of Test Plates
Test plate welds shall be radiographed full length using technique and acceptance standards of
paragraph 11.2 below. If results do not comply with acceptance standards, a new test plate shall be prepared.
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M-1002 APPENDIX W
4.7 Test Specimens Required

4.7.1 For tanks built of materials listed in Tables M10.1, M10.2, M10.3, M10.4, M10.5, M10.6,
and M10.7, the production-welded test plate dimensions shall be sufficient to provide one reduced-
section tension specimen conforming to Fig. W2A, 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.
4.7.2 For tanks built of materials listed in Tables M10.1, M10.5, and M10.7, include sufficient mate-
rial to provide three impact specimens each of weld metal and heat-affected zone, when required.
5.0 TYPES AND PURPOSES OF TESTS
5.1 Tension, Bend, and Fillet Tests
Three types of tests are used to evaluate welding procedure, welder performance, and production
welding.
5.1.1 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.
5.1.2 Bend tests
• Bend tests are used in welding procedure and welder performance qualification and pro-
duction-weld tests.
• Guided-bend tests are used to measure soundness and ductility of butt-welded joints.
5.1.3 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.
5.2 Impact Tests
5.2.1 Impact tests are used to evaluate welding procedures and production welding when the
tank service involves the transportation of a low-temperature product.
5.2.2 Charpy impact tests are used to measure notch toughness, at low temperatures, of weld
metal and weld heat-affected zone of butt welded joints.
5.3 Radiographic Tests
5.3.1 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 exami-
nation may be used as an alternative to mechanical tests for welder performance qualification.
5.3.2 Radiographic examination is recommended for welding procedure and production-welded
test plates to measure acceptance for preparation of test specimens.
5.4 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 M10.3, are not susceptible to intergranular attack asso-
ciated with precipitated chromium carbides and meet the acceptable corrosion rates listed in
Appendix M, paragraph 3.3.2.
5.5 Hardness Tests
Hardness tests are used to evaluate production welding and to control maximum hardness
requirements.
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APPENDIX W M-1002
6.0 TENSION SPECIMENS AND TESTS

6.1 Joint Tension Specimens
Flat, reduced-section tension specimens conforming to requirements of Fig. W2A, or turned
reduced-section tension specimens conforming to requirements of Fig. W2B, 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.
6.1.1 For thicknesses to and including 1 1/4 in. (31.8 mm), a single specimen shall be used.
6.1.2 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.
6.2 All-Weld-Metal Tension Specimens
6.2.1 The all-weld-metal tension specimen required for welding procedure qualification shall be
taken entirely from weld metal (at least the reduced section) and shall conform to the dimensional
requirements of Fig. W3.
6.2.2 This specimen is not required if the test plate thickness is less than 5/8 in. (15.9 mm).
6.3 Joint-Tension Tests
6.3.1 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 speci-
men, as measured before load is applied.
6.3.2 The tensile strength of the specimen shall be not less than
• the specified tensile strength of the base material as given in Table M10;
• the specified tensile strength of the weaker of the two, if base materials of different mini-
mum tensile strengths, as given in Table M10, are used.
6.3.3 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 ten-
sile strength of the base material as specified in Table M10.
6.4 All-Weld-Metal Tension Tests
6.4.1 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.
6.4.1.1 The elongation shall be not less than the value specified for base material in Table M10.
6.4.1.2 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.
6.4.2 The tensile strength shall be not less than
• the specified tensile strength of the base material as given in Table M10;
• the specified tensile strength of the weaker of the two, if base materials of different mini-
mum tensile strengths, as given in Table M10, are used.
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M-1002 APPENDIX W
7.0 BEND SPECIMENS AND TESTS

7.1 Guided-Bend Test Specimens
7.1.1 Guided-bend test specimens conforming to requirements of Fig. W4B and Fig. W5 shall be
used for qualification tests of welding procedures and welder performance and for production-
welded impact test plates.
7.1.2 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.
7.2 Guided-Bend Tests
7.2.1 Guided-bend specimens shall be bent in test jigs that are substantially in accord with Fig.
W6. 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 shall be forced steadily into the die 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.
7.2.2 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.
8.0 FILLET WELD SPECIMENS AND TESTS
8.1 Fillet Weld (Tee-Joint) Specimens
T-joint specimens, when required, shall conform to requirements of Fig. W7.
8.1.1 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. W7A.
8.1.2 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 struc-
ture of the weld metal and heat-affected zone. See Fig. W7B.
8.2 Fillet Weld Tests
8.2.1 The T-joint specimens prepared in accord with Fig. W7A shall contain no visible cracks.
8.2.2 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 spec-
imen 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.
8.2.3 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.
8.2.4 The procedure qualification T-joint weld shall have not more than 1/8 in. (3.18 mm) differ-
ence in the lengths of the legs of the fillet weld.
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APPENDIX W M-1002
8.2.5 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 com-
plete fusion at the joint root, but not necessarily beyond the root.
9.0 IMPACT, CORROSION AND HARDNESS TESTS
9.1 Impact Specimens and Tests
Impact tests are required only when specified in the tank specification.
9.1.1 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 speci-
fied, 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. W10.
9.1.2 Type, Location and Orientation of Specimens
Unless otherwise specified, specimens shall be Type A (10-mm × 10-mm Charpy V-notch), pre-
pared in accord with Fig. W11. 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. W10. The heat-affected zone notch shall be located in an area of maximum grain size, as deter-
mined by etching the specimen.
9.1.3 Test Procedure
Specimens shall be tested in accord with ASTM E23 at a temperature specified in the tank specifi-
cation. 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.
9.1.4 Test Results and Retests
9.1.4.1 Unless otherwise specified in the tank specification, the minimum impact test values of
full-size and subsize specimens shall be as shown in Table W2.
Table W2. 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
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M-1002 APPENDIX W
9.1.4.2 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.
9.1.4.3 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.
9.1.4.4 When an erratic result is caused by a defective specimen, or there is uncertainty in test
procedure, a retest shall be allowed.
9.1.5 Reports
9.1.5.1 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 direc-
tion; and weld metal and weld heat-affected zone impact value for each specimen tested.
9.1.5.2 The complete report of all impact tests shall be retained for not less than five years by the
tank fabricator, or by the car owner if the owner so requests.
9.2 Corrosion Specimens and Tests
Corrosion tests are required on tanks fabricated from materials listed in Table M10.3 when
required by the tank specification.
9.2.1 Material and number required
Test plates used to prepare specimens shall be provided from each heat of material used to fabri-
cate 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 speci-
mens shall be taken from the test plate, located as shown in Fig. W1B. Corrosion testing of the
base metal is not a requirement if the corrosion test has been conducted and certified by the mate-
rial 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.
9.2.2 Test criteria
9.2.2.1 Corrosion test specimens shall be considered to be acceptable when each exhibits corro-
sion rates not in excess of those listed in Appendix M, paragraph 3.3.2.
9.2.2.2 Weld corrosion test specimens need not be sensitized.
9.2.3 Reports
9.2.3.1 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 speci-
men tested.
9.2.3.2 The complete report of all corrosion tests shall be retained for not less than five years by
the tank fabricator, or by the car owner if the owner so requests.
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APPENDIX W M-1002
9.3 Hardness Tests

Hardness tests of production butt welds are required for pressure tank car tanks fabricated from
materials listed in Table M10.1.
9.3.1 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 intersec-
tions 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.
9.3.2 Hardness of weld shall not exceed Brinell 225 (Rockwell C20) after postweld heat treat-
ment.
9.3.3 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.
10.0 PROCEDURE AND PERFORMANCE QUALIFICATION
10.1 Scope
The rules of paragraphs 4.0, 5.0, 6.0, 7.0, 8.0, 9.0, 10.0, 11.0, 12.0, and 13.0 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.
10.2 Responsibility
10.2.1 Each facility shall be responsible for its welding and shall have on hand documentation
required by paragraph 10.3.
10.2.2 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.
10.2.3 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.
10.2.3.1 The certified facility shall be responsible for all welding. Use of subcontract welders by
an extension is not permitted.
10.2.3.2 All welding shall be performed in accordance with the certified facility’s welding proce-
dure specifications.
10.2.3.3 All welders shall be qualified by the certified facility in accordance with this specifica-
tion.
10.2.3.4 The certified facility’s 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.
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M-1002 APPENDIX W
10.3 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 com-
pany and shall be accessible to the AAR representative. Companies may centralize record storage.
Recommended forms for these records are shown in Figs. W12, W13, and W14.
10.4 Identification of Welds
Each qualified welder and welding operator shall be assigned an identifying number, letter, or
symbol by the facility. The assigned identification shall be used to identify the work of that welder
or welding operator.
10.5 Qualification Restrictions
10.5.1 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 15.9 below and with paragraph 15.4 or paragraph 15.5, also below, as applicable.
10.5.2 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.
10.5.3
10.6 Weld Orientation and Test Positions
10.6.1 The orientation of butt and fillet welds with respect to horizontal and vertical planes of
reference are classified as shown in paragraphs 10.6.2 through 10.6.6 below and in Fig. W8.
10.6.2 Butt welds (shown in Fig. W15.)
• Flat position 1G—plate in a horizontal plane with the weld metal deposited from above
• Horizontal position 2G—plate in a vertical plane with the axis of the weld horizontal
• Vertical position 3G—plate in a vertical plane with the axis of the weld vertical
• Overhead position 4G—plate in a horizontal plane with the weld metal deposited from
underneath
10.6.3 Fillet welds (shown in Fig. W16).
• Flat position 1F—plates so placed that the weld is deposited with its axis horizontal and
its throat vertical
• Horizontal position 2F—plate 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 3F—plates so placed that the weld is deposited with its axis vertical
• Overhead position 4F—plates so placed that the weld is deposited with its axis horizontal
on the under side of the horizontal surface and against the vertical surface
10.6.4 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. W8 and W9.
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10.6.5 Welders who pass the required groove or fillet weld tests listed in paragraphs 10.6.2 or
10.6.3 shall be qualified for the positions of groove welds and fillet welds shown in Table W3. Weld-
ing vertical down requires separate qualification.
Table W3. Performance qualification—position limitations

Qualification Test Position and Type of Weld Qualifieda/
Weld Position Groove Fillet
Plate—Groove 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
Special Positions (SP) SP, F SP, F
Plate—Fillet 1F — F
2F — F, H
3F — F,H,V
4F — F,H,O
3F and 4F — All
Special Positions (SP) — SP, F
a/ Welding positions (F=flat, H=horizontal, V=vertical, and O=overhead) are defined in
Figs. W8 and W9. Standard Test Positions (1G, 2G, 3G, 4G, 1F, 2F, 3F, and 4F) are
defined in paragraphs 10.6.2 and 10.6.3 and Figs. W15 and W16.
10.6.6 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. W8 and W9.
11.0 NONDESTRUCTIVE EXAMINATIONS AND ACCEPTANCE STANDARDS
11.1 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 11.2
• Liquid penetrant, paragraph 11.3
• Magnetic particle, paragraph 11.4
• Ultrasonic examination, paragraph 11.5
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11.2 Radioscopic Acceptance Criteria

11.2.1 General
11.2.1.1 A detailed procedure for the radiographic examination of welded joints shall be estab-
lished in accord with Appendix T by each facility.
11.2.1.2 A Level II NDT technician, qualified in accord with Appendix T, shall review and
approve all required radiographic examinations.
11.2.2 Acceptance Standards for Radiographed Welds
11.2.2.1 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.
11.2.2.2 Welds whose radiotapes show any of the following types of imperfections shall be unac-
ceptable:
• 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 thick-
ness 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
• Porosity in excess of that specified as acceptable in paragraphs 11.2.3 and 11.2.4 below
• Other round inclusions shall be judged on the same basis as porosity
11.2.3 Porosity
11.2.3.1 Images of a general circular or oval shape shall be interpreted as porosity for the pur-
pose of this standard. For radiography, the image will appear dark. For fluoroscopy, the image will
appear light.
11.2.3.2 Permissible porosity indications for weld thicknesses intermediate to those illustrated
shall be evaluated by comparison with porosity chart for the next thinner material or by calcula-
tion as shown in Table W4.
11.2.3.3 The total area of the porosity 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 porosity will be reduced in proportion.
11.2.3.4 In any 1-in. (25.4-mm) length of weld or 2T, whichever is smaller, porosity may be clus-
tered to a concentration four times that permitted by 0.060T in.2 (38.7T mm2). Such clustered
porosity shall be included in the porosity in any 6-in. (152-mm) length of weld that includes the
cluster.
11.2.3.5 Aligned porosity shall be acceptable provided the summation of the diameters of the
pores is no more than T in a length 12T or 6 in. (152 mm), whichever is less, provided each pore is
separated by a distance at least six times the diameter of the largest adjacent pore. Aligned poros-
ity indications shall be counted in the total area of permissible indications in any 6-in. (152-mm)
length of weld.
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11.2.3.6 The maximum pore dimension shall be 0.2T or 1/8 in. (3.18 mm), whichever is smaller,
except that an isolated pore separated from an adjacent pore by 1 in. (25.4 mm) or more may be
0.3T or 1/4 in. (6.35 mm), whichever is less.
Table W4. Maximum permissible porosity indications in radiotapes per 6-in. length of weld—conventional units
Total Area Large Pore Size Medium Pore Size Fine Pore Size
Weld of Permitted Approx. Decimal Approx. Decimal Approx. Decimal
Thick- Porosity, Fraction, Value, Fraction, Value, Fraction, Value,
ness, 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 porosity.
Table W5. Maximum permissible porosity indications in radiographs per 15.2-mm length of weld—SI units
Total Area of Large Pore Size Medium Pore Size Fine Pore Size
Weld
Permitted
Thick- Decimal Value, Decimal Value, Decimal Value,
Porosity, No. No. No.
ness, mm mma/ mma/ mma/
mm2
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 porosity.
11.2.4 Porosity Charts
11.2.4.1 The porosity charts, Figs. W17 through W20, illustrate various types of assorted and
uniform, randomly dispersed porosity indications. The chart for each thickness represents the
maximum acceptable porosity. The charts represent full-scale 6-in. radiographs and shall not be
enlarged or reduced. The porosity 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
porosity indications differ significantly from the porosity charts, the actual numbers and sizes of
the pores may be measured and the total area of porosity calculated.
11.2.4.2 Porosity charts are identical with the 1974 edition of Section VIII, Division 1 of the
ASME Boiler and Pressure Vessel Code, Appendix 4, published by the American Society of
Mechanical Engineers, 345 East 47th Street, New York, New York, 10017, and are reproduced by
permission.
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11.3 Liquid Penetrant Examination Acceptance Criteria

11.3.1 General
11.3.1.1 This section describes methods that shall be employed whenever liquid penetrant exam-
ination is specified in this specification or in a tank specification. A Level II NDT technician, qual-
ified in accord with Appendix T, shall review and approve all required liquid penetrant
examinations.
11.3.1.2 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.
11.3.2 Evaluation of Indications
An indication is the evidence of a mechanical imperfection. Only indications with major dimen-
sions greater than 1/16 in. shall be considered relevant.
11.3.2.1 A linear indication is one having a length greater than three times the width.
11.3.2.2 A rounded indication is one of circular or elliptical shape with the length equal to or less
than three times the width.
11.3.2.3 Any questionable or doubtful indications shall be reexamined to determine whether or
not they are relevant.
11.3.3 Acceptance Standards
11.3.3.1 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 reexamina-
tion, by the same method or by the use of other nondestructive methods and/or by surface condition-
ing, that no unacceptable imperfection is present.
11.3.3.2 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.
11.4 Magnetic Particle Examination Acceptance Criteria
11.4.1 General
approve all required magnetic particle examinations.
11.4.1.2 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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11.4.2 Evaluation of Indications

Indications will be revealed by retention of magnetic particles. All such indications are not neces-
sarily imperfections, however, because excessive surface roughness, magnetic permeability varia-
tions (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.
11.4.2.1 A linear indication is one having a length greater than three times the width.
11.4.2.2 A rounded indication is one of circular or elliptical shape with a length equal to or less
than three times its width.
11.4.2.3 Any questionable or doubtful indications shall be reexamined to determine whether or
not they are relevant.
11.4.3 Acceptance Standards
11.4.3.1 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 reexamina-
tion, by the same method or by the use of other nondestructive methods and/or by surface condi-
tioning, that no unacceptable imperfection is present.
11.4.3.2 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.
11.5 Ultrasonic Examination Acceptance Criteria
11.5.1 General
approve all required ultrasonic examinations.
11.5.1.2 For groove welds in butt joints on carbon steel tanks (other than tank shell joints of new
tanks), ultrasonic examination may be employed in accord with Appendix T.
11.5.2 Evaluation and Acceptance Criteria
Evaluation and acceptance of indications shall be in accord with Appendix 12, Paragraph 12-3 of
ASME Boiler and Pressure Vessel Code, Section VIII, latest revision, 1988 Addenda. Any indica-
tion 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 sur-
face conditioning, that no unacceptable imperfection is present.
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12.0 PERFORMANCE QUALIFICATION OF WELDERS AND WELDING OPERATORS

12.1 Qualification of Welders
Each welder shall pass the mechanical tests prescribed in paragraph 12.6 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 12.6 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 12.4 below.
12.1.1 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.
W4A, W15, W21C, and W21D). 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 thick-
nesses, both within the range of essential variables as recorded in the welder’s “Record of Welder
Performance Qualification Test” (see Fig. W14).
12.1.2 Performance qualification tests for fillet welds, only, may be made using fillet-welded test
plates (see Figs. W7A and W16. 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 welder’s “Record of Welder Performance Qualifica-
tion Test” (see Fig. W14).
12.2 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 auto-
matic 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 per-
formance-qualified.
12.2.1 A 3-ft (914-mm) length of weld made by the operator shall be radiographed using the tech-
nique of paragraph 11.0 above. To qualify the operator’s 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.
12.2.2 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 radio-
graphed, 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.
12.2.3 The results of the radiographic examination shall be recorded and retained by the facility.
The radiographs may be retained or be discarded.
12.3 Weldments Involving Combination of Processes
12.3.1 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 perfor-
mance-qualified.
12.3.2 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 W7.
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12.4 Essential Variables

When any of the applicable changes in the essential variables as described in paragraph 16.2
below and in Table W6 are made, the welder must be requalified.
Table W6. Essential variables—performance qualification
Welding Process (references are to paragraph numbers in this appendix)
SMAW GTAW GMAW, FCAW SAW
Joints—paragraph 16.2.1 16.2.1.1, 16.2.1.2 16.2.1.1, 16.2.1.2 16.2.1.1, 16.2.1.2 16.2.1.1, 16.2.1.2
Base Metals—paragraph 16.2.2 16.2.2.2, 16.2.2.3 16.2.2.2, 16.2.2.3 16.2.2.2, 16.2.2.3 16.2.2.2, 16.2.2.3
Filler Metals—paragraph 16.2.3 16.2.3.10 16.2.3.11, 16.2.3.13 16.2.3.11, 16.2.3.13
Positions—paragraph 16.2.4 16.2.4.1 16.2.4.1 16.2.4.1 16.2.4.1
Electrical—paragraph 16.2.7 16.2.7.2 16.2.7.1
Shielding Gas or Flux—paragraph 16.2.8 16.2.8.2 16.2.8.2
Technique—paragraph 16.2.9 16.2.9.5, 16.2.9.6 16.2.9.5, 16.2.9.6 16.2.9.5, 16.2.9.6 16.2.9.6
12.5 Test Joints
12.5.1 Information regarding the essential variables in paragraph 12.4 above (base material,
filler metal, welding position, etc.) shall be recorded in the facility’s “Record of Welder Performance
Qualification Test” prepared for each welder qualified (see Fig. W14.) Other details that are essen-
tial 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 12.1, 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.
12.5.2 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. W7A.
12.5.3 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:
12.5.3.1 The total alloy content of the base metal, for which carbon steel base metal is substi-
tuted, shall not exceed a nominal 6%. The total alloy content of the weld metal used shall not
exceed this nominal 6%.
12.5.3.2 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 W12. No preheating or postheating is required.
12.5.3.3 When alloy steel filler metals as permitted in paragraph 12.5.3.1 above are used on car-
bon steel plate, the test specimens are to be preheated and postheated in accord with the WPS.
12.5.4 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.
12.5.5 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.
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12.6 Test Specimens

12.6.1 The qualification test weld shall be visually inspected in the as-welded condition (no
grinding after completing the weld) in accordance with paragraphs 15.4 and 15.9 below, except
that reinforcement may be up to 1/8 in. For welder performance qualification by mechanical test-
ing, the type and number of test specimens required, together with the range of thickness of mate-
rials for which a welder is qualified by use of a given thickness of test plate, are shown in Table
W7. When alternative qualification by radiographic or ultrasonic examination of groove welds is
used as permitted in paragraph 12.1, the range of thickness of materials for which a welder is
qualified shall be the same as for mechanical testing in Table W7.
12.6.2 Test specimens may be removed from the welded test plates in any order, but in a manner
similar to that shown in Figs. W21C and W21D.
12.6.3 All test specimens shall be prepared, tested and meet the requirements as prescribed in
applicable portions of paragraphs 7.0, 8.0, and 10.0 of this appendix. When alternative qualifica-
tion by radiographic or ultrasonic examination of groove welds is used as permitted in
paragraph 12.1, the radiographic or ultrasonic acceptance standards of the applicable portions of
paragraph 11.0 above shall be used.
12.6.4 The number of test plates (and sets of test specimens) required by Table W7 shall be pre-
pared 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 W7. Performance qualification tests required
Range of Thickness of Type and Number of Tests Required
Material Qualified by
Test Plate, in. (mm) Guided-Bend Test
Type Side- Face- Root-
of Thickness (t) of Test Plate Bend Bend Bend Fillet Tee-
Joint As-Welded, in. (mm) Min. Max. Fig. W5Cb/c/d/ Fig. W5Ac/ Fig. W5Bc/ Jointa/
1/16e/
Butt 1/16 (1.59) to 3/8 (9.5 incl.)
(1.59e/) 2t 1 1
Over 3/8 (9.5) but less than 1/2 (12.7) 3/16 (4.76) 2t 1 1
Butt or
Over 3/8 (9.5) but less than 1/2 (12.7) 3/16 (4.76) 2t 2
Max. to be
Butt 1/2 (12.7) and over 3/16 (4.76) weldedf/ g/ 2
Fillet Fig. W7A All thicknesses 1
a/ Required only when qualification is desired to make fillet welds only.
b/ For aluminum alloy 6061, use Fig. W5D.
c/ Longitudinal face-bend and longitudinal root-bend tests (Fig. W4B) 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 12.6.3 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 maxi-
mum 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.
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12.7 Retests
A welder who fails the performance qualification tests may be retested under the following condi-
tions:
12.7.1 If one or more of the test specimens prescribed in Table W7 fails to meet the requirements,
or if the qualification failed has been that of the alternative qualification by radiographic examina-
tion of paragraph 12.6 above.
12.7.1.1 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.
12.7.1.2 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.
12.7.2 If the performance qualification test failed was by radiographic or ultrasonic examination,
the retest shall be by the radiographic or ultrasonic examination method, respectively.
12.8 Renewal of Qualification
Renewal of qualification of welders and welding operators used to fabricate, repair, alter, or con-
vert AAR-approved tanks is required under the following circumstances:
12.8.1 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 W3.
12.8.2 When there is specific reason to question the welder’s 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 W3.
13.0 PROCEDURE QUALIFICATION
13.1 Qualification of Procedures
13.1.1 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 param-
eters 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.
13.1.2 Except for steels having their mechanical properties enhanced by quenching and temper-
ing, procedure qualification tests for butt and fillet welds shall be made using butt-welded test
plates (see Figs. W4A, W15, W21A, and W21B). Procedures used for deposits of metal applied to
the surface (except those covered by paragraph 13.7 below) shall be qualified by using butt-welded
test plates. 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. W12.)
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M-1002 APPENDIX W
13.1.3 For steels having their mechanical properties enhanced by quenching and tempering, pro-
cedure qualification tests for butt welds shall be made using butt-welded test plates (see Figures
Figs. W4A, W15, W21A, and W21B), and tests for fillet welds shall be made using fillet-welded test
plates (see Figs. W7B and W16). 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 circu-
lar attachments to the shell, within the range of essential variables of its WPS. (See Fig. W12.)
13.1.4 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 W2. Table W9, 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 17.9.2 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.
When any of the applicable changes in the essential variables, as described in paragraph 16.2
below and in Tables W8 and W9, 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 W8. Essential variables—welding procedures
Welding Process
Joints—paragraph 16.2.1 16.2.1.1, 16.2.1.2 16.2.1.1, 16.2.1.2 16.2.1.1, 16.2.1.2 16.2.1.1, 16.2.1.2
Base Metals—paragraph 16.2.2 16.2.2.1, 16.2.2.4, 16.2.2.1, 16.2.2.4, 16.2.2.1, 16.2.2.4, 16.2.2.1, 16.2.2.4,
16.2.2.7 16.2.2.7 16.2.2.7, 16.2.2.8 16.2.2.7
Filler Metals—paragraph 16.2.3 16.2.3.1, 16.2.3.2, 16.2.3.1, 16.2.3.2, 16.2.3.1, 16.2.3.2, 16.2.3.1, 16.2.3.2,
16.2.3.18 16.2.3.3, 16.2.3.4, 16.2.3.3, 16.2.3.5, 16.2.3.6, 16.2.3.7,
16.2.3.12, 16.2.3.6, 16.2.3.7, 16.2.3.8, 16.2.3.9,
16.2.3.18 16.2.3.8, 16.2.3.9, 16.2.3.12,
16.2.3.12, 16.2.3.18 16.2.3.17,
16.2.3.18
Preheat—paragraph 16.2.5 16.2.5.1 16.2.5.1 16.2.5.1 16.2.5.1
Postweld heat treatment— 16.2.6 16.2.6 16.2.6 16.2.6
paragraph 16.2.6
Electrical—paragraph 16.2.7 16.2.7.4 16.2.7.1
Shielding Gas or Flux— 16.2.8.1, 16.2.8.2 16.2.8.1, 16.2.8.2 16.2.8.4, 16.2.8.5
paragraph 16.2.8
Technique—paragraph 16.2.9 16.2.9.5, 16.2.9.6 16.2.9.2, 16.2.9.5, 16.2.9.2, 16.2.9.5, 16.2.9.3, 16.2.9.6
16.2.9.6 16.2.9.6
10/2007 C-III [M-1002] 469

APPENDIX W M-1002
Table W9. Supplementary essential variables—welding procedures

when notch toughness required by tank car specification
Welding Process
Joints—paragraph 16.2.1 16.2.1.3 16.2.1.3 16.2.1.3 16.2.1.3
Base Metals—paragraph 16.2.2 16.2.2.5, 16.2.2.6, 16.2.2.5, 16.2.2.6, 16.2.2.5, 16.2.2.6, 16.2.2.5, 16.2.2.6,
16.2.2.9 16.2.2.9 16.2.2.9 16.2.2.9
Filler Metals—paragraph 16.2.3 16.2.3.14, 16.2.3.15 16.2.3.15, 16.2.3.16
16.2.3.15
Positions—paragraph 16.2.4 16.2.4.2 16.2.4.2 16.2.4.2
Preheat—paragraph 16.2.5 16.2.5.2 16.2.5.2 16.2.5.2 16.2.5.2
Electrical—paragraph 16.2.7 16.2.7.3 16.2.7.3 16.2.7.3 16.2.7.3
Shielding Gas or Flux— 16.2.8.3
paragraph 16.2.8
Technique—paragraph 16.2.9 16.2.9.1, 16.2.9.4 16.2.9.1, 16.2.9.4 16.2.9.1, 16.2.9.4
Table W10. F-Numbers for steel filler metals—grouping 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
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M-1002 APPENDIX W
Table W11. A-Numbers—classification 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 0.40–0.65 — 1.60 1.00
3 Chrome (0.4% to 2%)- 0.15 0.40–2.00 0.40–0.65 — 1.60 1.00
Molybdenum
4 Chrome (2% to 6%)-Molybdenum 0.15 2.00–6.00 0.40–1.50 — 1.60 2.00
5 Chrome (6% to 10.5%)- 0.15 6.00–10.50 0.40–1.50 — 1.20 2.00
Molybdenum
6 Chrome-Martensitic 0.15 11.00–15.00 0.70 — 2.00 1.00
7 Chrome-Ferritic 0.15 11.00–30.00 1.00 — 1.00 3.00
8 Chromium-Nickel 0.15 14.50–30.00 4.00 7.50–15.00 2.50 1.00
9 Chromium-Nickel 0.30 25.00–30.00 4.00 15.00–37.00 2.50 1.00
10 Nickel to 4% 0.15 0.55 0.80–4.00 1.70 1.00
11 Manganese-Molybdenum 0.17 — 0.25–0.75 0.85 1.25–2.25 1.00
12 Nickel-Chrome-Molybdenum 0.15 1.50 0.25–0.80 1.25–2.80 0.75–2.25 1.00
a/ Single values shown above are maximum.
Table W12. F-Numbers for nonferrous filler metals—grouping 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
10/2007 C-III [M-1002] 471

APPENDIX W M-1002
13.3 Test Joints

13.3.1 The base material, the filler metal, and the welding procedure shall comply with the appli-
cable WPS. Information regarding the essential variables in paragraph 13.2 above shall be
recorded in the facility’s PQR’s prepared for each procedure qualified (See Fig. W12). The dimen-
sions of the test plates and the length of the welds shall be sufficient to provide the required test
specimens.
13.3.2 The dimension for plates used for fillet welds shall be as noted in Fig. W7B.
13.3.3 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.
13.3.4 Weld grooves for thicknesses less than 5/8 in. (15.9 mm) shall be prepared by thermal pro-
cesses when such processes are to be employed during fabrication of quenched and tempered mate-
rials. 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.
13.4 Test Specimens
13.4.1 Radiography of the full length of test plate welds is recommended using technique and
acceptance standards of paragraph 11.2 above. If results do not comply with acceptance standards,
a new test plate shall be prepared.
13.4.2 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 W13.
13.4.3 Test specimens shall be removed in the order shown in Figs. W4B, W7B, W21A, and
W21B.
13.4.4 All test specimens shall be prepared and tested and meet the requirements as prescribed
in applicable portions of paragraphs 6.0, 7.0, 8.0, 10.0, and 11.2 of this appendix.
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M-1002 APPENDIX W
13.4.5 The number of test plates (and sets of test specimens) required by Table W13 shall be pre-
pared and tested to provide procedure qualification that will be used in the fabrication, repair,
alteration, or conversion of AAR-approved tanks.
Table W13. 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
Face- Root- Tee-
Side-Bend Bend Fig. Bend Fig. Joint
Thickness (t) of Test Plate Fig. W5C W5A W5B Fig. W7B
As-Welded, in. (mm) Min. Max. Fig. W2 Fig. W3 c/d/ d/ d/ e/
1/16 (1.59) to 3/8 (9.5) incl. 1/16f/ 2t 2 2 2

(1.59f/)
Over 3/8 (9.5) but less than 3/4 (19.0) 3/16 2tg/ 2 1h/ 2 2
(4.76)
or 3/16
Over 3/8 (9.5) but less than 3/4 (19.0) (4.76) 2tg/ 2 1h/ 4
3/4 (19.0) and over 3/16 2tg/ 2 1 4
(4.76)
Fillet (Fig. W7B) All thicknesses 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 require-
ment of the procedure qualification and taken at test plate locations as shown in Figs. W21A and W21B.
c/ For aluminum alloy 6061, use Fig. W5D.
d/ Longitudinal face-bend and longitudinal root-bend tests (Fig. W4B) 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.
e/ Required only for ferritic steels having their mechanical properties enhanced by quenching and tempering.
f/ 0.5t for nonferrous materials, but not less than 1/16 in. (1.59 mm).
g/ 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.
h/ Not required for test plate thickness less than 5/8 in. (15.9 mm).
10/2007 C-III [M-1002] 473

APPENDIX W M-1002
13.5 Retests
When one or more of the test specimens in Table W13 fail to meet the requirements, a retest may
be made under the following conditions:
13.5.1 When failure of specimens can be attributed to welder performance, an immediate retest
may be made.
13.5.2 When failure of specimens can be attributed to essential variables of the WPS, make nec-
essary changes and make a new qualification test.
13.6 Renewal of Qualification
Once a welding procedure is qualified, it shall continue in effect indefinitely, within the range of its
essential variables.
13.7 Weld Buildup
Following are the required essential variables and testing specifications that must be followed in
order to qualify a weld buildup procedure made by the temper bead technique, as described in
Appendix R, paragraph 11.5.
13.7.1 Essential variables
The welding procedure must be set up as a new procedure and must be requalified when any of the
following changes are made:
• A change from one welding process to any other process, or combination of processes
• A change in base metal specified maximum chemical analysis (e.g. from ASTM A285 Grade
C to ASTM A515 Grade 70) that increases the carbon equivalent. Carbon equivalent for-
mula is as follows:
Mn Cr Mo V Ni Cu
C.E. = C + -------- + ------ + -------- + ---- + ------ + -------
6 5 5 5 15 15
• A change in the composition of the weld filler metal from one F-number to another F-num-
ber and/or from one A-number to another A-number
• The addition of other welding positions than those already qualified
• A decrease in the preheat temperature qualified
• A decrease in the interpass temperature qualified
• A change from a multiple-layer to a single-layer overlay
• A decrease in the heat input under that qualified. The heat input formula is as follows:

Voltage × Amperage × 60 Voltage × Amperage × 60
Heat input (J/in.) = -------------------------------------------------------------- Heat input (J/cm) = --------------------------------------------------------------
Travel Speed (in./min) Travel Speed (cm/min)
• When welding in the vertical position, a change from uphill to downhill, or vice versa
• For submerged arc welding, a change in the nominal composition or type of flux used
Requalification is not required for a change in flux particle size
• A change in the number of electrodes acting on the same welding puddle
• The addition or omission of supplementary filler metal to the welding arc
• For machine or automatic welding, the addition or elimination of oscillation of the elec-
trode or electrodes
• A change from a single gas to any other single gas, or to a mixture of gases, or vice versa; a
change in specified percentage composition of gas mixture or omission of shielding gas; a
decrease of 10% or more in the rate of flow of shielding gas or mixture.
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M-1002 APPENDIX W
13.7.2 Testing
The testing plate shall be of equal or greater thickness than the base metal used in production.
The test plate shall be a minimum of 12 in. long and 6 in. wide (305 mm long and 153 mm wide).
13.7.3 Examination
13.7.3.1 The weld buildup surface shall be examined using the liquid penetrant or magnetic par-
ticle method. The examination shall meet the requirements and acceptance standards of
paragraph 11.3 or paragraph 11.4 as applicable. Radiographic examination per paragraph 5.3.2 is
not required.
13.7.3.2 Following the liquid penetrant examination, four guided bend tests shall be made from
the test coupon. The test specimens shall be cut so that there are four specimens perpendicular to
the direction of welding (see Fig. W23). The bend specimen face may be ground smooth, but not
more than 1/16 in. (1.59 mm) of the overlay may be removed.
The guided bend specimens shall have no open defects in the weld or heat-affected zone exceeding
1/8 in. (3.18 mm), measured in any direction on the convex surface of the specimen after bending.
Cracks occurring on the corners of the specimen during testing shall not be considered, unless
there is definite evidence that they result from slag inclusions or other internal defects.
13.7.3.3 The first and last weld bead shall have a portion sectioned out of them to be polished,
etched, and micro-hardness tested in accord with ASTM E384. Acceptable hardness values shall
not exceed 285 HV2000 (Vickers) or 320 HK500 (Knoop). In accord with Fig. W24, a minimum of
three indentations shall be taken in the base metal, in the heat-affected zone, and in the weld
metal, a total of not less than nine indentations.
14.0 FABRICATION
14.1 Forming
Forming of plates shall be done by pressure and not by impact. This includes the edges of the
plates forming longitudinal joints.
14.2 Cutting to Size
14.2.1 Ferrous and nonferrous plates, edges of heads, and other parts may be cut to size and
shape by mechanical means such as matching, shearing, or grinding or by applicable types of oxy-
gen (flame) or arc cutting.
14.2.2 Oxygen- or arc-cut edges shall be uniform and smooth and shall be free of all loose scale
and slag prior to welding on the edges. 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.
14.3 Alignment
14.3.1 Plates and heads that are being welded shall be fitted, aligned, and retained in position
during the welding operation.
14.3.2 Bars, jacks, clamps, or other appropriate devices, including tack welds, may be used to
hold in alignment the edges to be welded. Tack welds shall be removed, unless they are made with
filler metal that meets the minimum mechanical properties of the welded joint and will not be det-
rimental to subsequent welding.
14.3.3 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 manu-
facturer shall demonstrate that the required effective weld size has been obtained.
14.3.4 For butt welding of plates of unequal thickness, see Appendix E.
10/2007 C-III [M-1002] 475

APPENDIX W M-1002
14.4 Cleaning
The surfaces to be welded shall be cleaned of any foreign substance that will be detrimental to
weld quality. Surfaces shall be cleaned at least 0.5 in. (12.7 mm) from the welding edge for ferrous
materials and 2 in. (50.8 mm) for nonferrous materials. See paragraph 14.2.2 above.
14.5 Welding Conditions
14.5.1 Welding shall not be done when the temperature of the base material 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 temperature
warm to the hand [estimated to be above 60 °F (15.6 °C)] before welding is started.
14.5.2 Welding shall not be done when the surfaces of the parts to be welded are wet. Unless the
welder and work are properly shielded, welding shall not be done when rain or snow is falling, nor
during periods of high winds.
14.6 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.
14.7 Tolerance for Heads
See Appendix E, paragraph 2.2, for permissible deviation of a head from the specified shape.
14.8 Arc Strikes
Cracks or blemishes (visible marks) caused by arc strikes shall be removed. The removal of any
cracks shall be confirmed by liquid penetrant or magnetic particle inspection; reference Appendix
T, paragraph 4.0 or 5.0, respectively.
15.0 WELD JOINTS
15.1 Cleaning During Welding
When weld metal is to be deposited over a previously welded surface, all slag shall be removed by
a roughing tool, chisel, air chipping hammer, or other suitable means, so as to prevent inclusion of
impurities in the weld metal.
15.2 Groove Preparation for Back Weld
For double-welded butt joints, the groove for the back weld shall be prepared by mechanical
means, such as chipping or grinding, or by arc, plasma arc, or oxygen gouging. The groove shall be
such as to provide sound metal at the base of weld metal first deposited. These requirements are
not intended to apply to any welding procedure by which proper fusion and penetration are other-
wise obtained and no impurities remain at the base of the weld metal first deposited.
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M-1002 APPENDIX W
15.3 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 W14. Joints within tank heads and dome
heads shall meet the requirements in Table W14 for longitudinal joints.
Table W14. 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.
15.4 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.
15.4.1 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 11.2.1 and 15.9 of this appen-
dix.
15.4.2 For a single-welded butt joint with backing strip, the requirements for reinforcement
apply only to the side opposite the backing strip.
15.5 Fillet Welds
15.5.1 Concavity and convexity shall fall within the ranges shown in Table W15. This is in addi-
tion to meeting minimum fillet weld size.
15.5.2 Weld metal shall be deposited in such a way that adequate penetration into the base metal
at the root of the weld is secured.
15.5.3 Toes of fillet welds shall blend smoothly into base metal.
Table W15. 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)
15.6 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.
10/2007 C-III [M-1002] 477

APPENDIX W M-1002
15.7 Identification of Welds

15.7.1 Each welder and welding operator shall stamp his or her identifying number, letter, or
symbol, assigned by the fabricator, adjacent to and at intervals of not more than 3 ft along the
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.
15.7.2 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.
15.7.3 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 to the inspector.
15.8 Repair of Defects
Defects in welded joints shall be repaired by removing the defect and rewelding. The defect shall
be removed by mechanical means or by air-carbon arc or plasma arc gouging.
15.9 Surface Quality of Welds
15.9.1 The finish of the welded joint shall be free of cracks and slag. Weld surfaces shall be rea-
sonably smooth and be free from irregularities, grooves, depressions, surface porosity, undercuts,
and other defects detrimental to weld quality. Undercutting shall not be in excess of 0.010 in. and
shall not reduce the thickness below the minimum required value in the tank shell and tank head
butt welds and the tank side of fillet welds.
15.9.2 Welded joints in draft sills and underframes, including corners, shall be constructed in
such a manner as to limit undercutting to values permitted by AWS D15.1.
15.10 Flux
15.10.1 All submerged melt welding composition handling equipment shall be of a design, loca-
tion, and support that will minimize any tendency toward separation or segregation as a conse-
quence of variations in particle size or density.
15.10.2 All containers and reservoirs used for submerged melt welding composition shall be so
designed that they will empty in normal usage with no residue remaining.
15.10.3 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).
15.10.4 Recycling of used flux as a separate operation shall remove harmful dusts and foreign
materials.
15.10.5 Where fused flux (slag) is recrushed, net recovered (including crushed) material shall be
blended with not less than 25% by weight new flux.
15.10.6 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).
15.10.7 Recrushed slag residue from alloying type fluxes shall not be used.
15.10.8 Flux from damaged packages shall be discarded or shall be dried at a minimum tempera-
ture of 500 °F (260 °C) for one hour before use. Flux that has been wet shall not be used.
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M-1002 APPENDIX W
15.11 Low Hydrogen Electrodes

When welding procedures involve the use of low hydrogen electrodes, they must be handled in
accord with the following requirements:
15.11.1 Store electrodes in ovens at 250 °F (121 °C) minimum after removing electrodes from a
hermetically sealed container or from a drying oven.
15.11.2 Dry or redry electrodes at the temperature and time shown in Table W16 if
• the seal on a hermetically sealed container is damaged.
• allowable exposure time to atmosphere per Table W16 is exceeded.
15.11.3 Electrodes must not be redried more than once.
15.11.4 Discard electrodes that have been wet.
Table W16. 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 °F–500 °F 2
(232 °C–260 °C)
AWS A5.5/CSA W48.3 Low Alloy Steel E70##-X 4 700 °F–800 °F 1
E80##-X 2 700 °F–800 °F 1
E90##-X 1 700 °F–800 °F 1
E100##-X 1/2 700 °F–800 °F 1
E110##-X 1/2 700 °F–800 °F 1
(371 °C–427 °C)
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, established by testing, may be used per Paragraph 11.6.3 of AWS
D15.1, Railroad Welding Specification.
16.0 WELDING DATA
16.1 Welding Variables
Each welding variable described in this section is applicable as an essential variable when speci-
fied in paragraph 12.0 or paragraph 13.0 above.
16.2.1 Joints
16.2.1.1 The omission or addition of consumable inserts.
16.2.1.2 The deletion of the backing in single-welded butt joint welds. Double-welded groove
welds are considered welding with backing.
16.2.1.3 A change in the edge preparation that would make a groove angle smaller, make groove
root radius smaller, make joint nose thicker, or decrease joint gap.
10/2007 C-III [M-1002] 479

APPENDIX W M-1002
16.2.2 Base Metals

16.2.2.1 A change from a base material having one P-number to a material having another P-
number, or to any other base material. 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 M10, 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 materi-
als, 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.
16.2.2.2 A change in either or both base materials from a nonferrous material shown with one
P-number in Appendix M, Table M10, 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 M10.2 will not require requalification.
16.2.2.3 A change in base material thickness beyond the range qualified in accord with Table W7.
16.2.2.4 A change in base material thickness beyond the range qualified in accord with Table
W13.
16.2.2.5 Welding procedure qualifications shall be made using a base metal of the same type or
grade as the base metal to be used in production welding. When joints are to be made between two
different base metals, a procedure qualification shall be made for the applicable combination of
base metals, even though procedure qualification tests have been made for each of the two base
metals welded to itself. If, however, the procedure specification for welding the combination of base
metals specifies the same essential variables, including electrode or filler metal, as both specifica-
tions for welding each base metal to itself, such that base metals is the only change, it shall not be
necessary to make impact tests to qualify the two together. In addition, when two different base
metals are qualified using a single test coupon, that coupon qualifies the welding of these two to
themselves, as well as to each other, using the variables qualified.
16.2.2.6 The minimum thickness qualified for production weld 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 min-
imum thickness qualified is 1/2T.
16.2.2.7 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.
16.2.2.8 For the short-circuiting transfer mode of the gas metal-arc process, when the qualifica-
tion 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.
16.2.2.9 An increase in Cb or Cb+V in TC128 Grade B, when Cb exceeds 0.025% as specified by
the purchaser, as permitted by ASTM A20.
C-III [M-1002] 480 10/2007

M-1002 APPENDIX W
16.2.3 Filler Metals

16.2.3.1 A change from one F-number in Tables W10 and W12 to any other F-number, or to any
other filler metal not listed in Tables W10 and W12.
16.2.3.2 For the ferrous metals in Table W9, a change in the chemical composition of the weld
deposit from one A-number to any other A-number in Table W9. Qualification with A-No. 1 shall
qualify for A-No. 2 and vice versa. In lieu of an A-number designation, the nominal chemical com-
position of the weld deposit shall be indicated on the PQR and WPS. Designation of nominal chem-
ical composition may also be by reference to the AWS classification (where such exists), the
manufacturer’s trade designation, or other established procurement documents.
16.2.3.3 A change from a nonferrous filler metal listed with one AWS classification number in
Table W12 to a filler metal listed with another classification number, or to any other filler metal.
16.2.3.4 The deletion or addition of filler metal.
16.2.3.5 A change in the consumable electrode from bare (solid) to flux cored, to covered, or vice
versa.
16.2.3.6 The addition or deletion of supplemental filler metal.
16.2.3.7 The addition or deletion of supplemental powdered filler metal.
16.2.3.8 An increase in the amount of supplemental powdered filler metal.
16.2.3.9 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 specifica-
tion range of chemistry given in the procedure specification.
16.2.3.10 A change from one F-number in Tables W10 and W12 to any other F-number, or to any
other filler metal, except qualification under any F-number up to and including F-No. 5 shall qual-
ify a welder for all lower F-numbers.
16.2.3.11 Qualification with an F-No. 2X aluminum filler metal shall qualify to weld with any
other F-No. 2X filler metal.
16.2.3.12 If filler metal does not have an AWS classification that defines chemical limits, a
change in weld wire brand name or grade.
16.2.3.13 A change from one F-number in Table W10 to any other F-number, or to any other filler
metal not listed in Table W10, except that deposited weld metal using a bare rod not covered by an
AWS specification that conforms to an analysis listed in Table W11, shall be considered to be clas-
sified as F-No. 6.
16.2.3.14 A change in the nominal diameter of the electrode to over 1/4 in. (6.35 mm).
16.2.3.15 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.
16.2.3.16 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 con-
dition.
10/2007 C-III [M-1002] 481

APPENDIX W M-1002
16.2.3.17 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 classi-
fied by AWS specifications.
• the flux trade name for A-No. 8 deposits.
16.2.3.18 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.
16.2.4 Positions
16.2.4.1 The addition of welding positions other than those already qualified. See paragraph 10.6
above.
16.2.4.2 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.
16.2.5 Preheat
16.2.5.1 A decrease of 100 °F (55.6 °C) or more in the minimum specified preheating tempera-
ture.
16.2.5.2 An increase of more than 100 °F (55.6 °C) in the maximum interpass temperature
recorded on the PQR.
16.2.6 Postweld heat treatment
A change in the postweld heat treatment temperature and time cycle range specified for ferrous
materials. The time cycle may be specified as varying with thickness and with time at tempera-
ture. For example: 1 hour per inch (1 hour per 25.4 millimeters) of thickness; and as shown in
Table W17.
16.2.7 Electrical
16.2.7.1 A change from spray arc, globular arc, or pulsed arc to short-circuiting arc, or vice versa.
16.2.7.2 A change from AC to DC, or vice versa. In DC welding, a change from direct current elec-
trode negative (straight polarity) to direct current electrode positive (reverse polarity), or vice
versa.
16.2.7.3 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:
16.2.7.3.1 Heat input

Voltage × Amperage × 60 Voltage × Amperage × 60
Heat input (J/in.) = -------------------------------------------------------------- Heat input (J/cm) = --------------------------------------------------------------
Travel Speed (in./min) Travel Speed (cm/min)
16.2.7.3.2 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.
16.2.7.4 In the gas tungsten-arc process, a change from AC to DC, or vice versa. In DC welding, a
change from straight polarity to reverse polarity, or vice versa.
C-III [M-1002] 482 10/2007
M-1002 APPENDIX W
16.2.8 Shielding Gas or Flux

16.2.8.1 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.
16.2.8.2 In gas-shielded arc welding processes, the omission of gas backing.
16.2.8.3 A change in flux brand name or grade.
16.2.8.4 A change in flux involving either addition or deletion of any material of screen size finer
than 200 mesh (79 per 10 mm).
16.2.8.5 A change in flux involving the use of recrushed flux.
16.2.9 Technique
16.2.9.1 A change in width, frequency, or dwell time of oscillation for machine or automatic weld-
ing only.
16.2.9.2 In machine welding, a change from single arc to multiple arc, or vice versa.
16.2.9.3 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 shall preferably be made on a production weld.
16.2.9.4 A change from single electrode to multiple electrode, or vice versa, for machine or auto-
matic welding only.
16.2.9.5 A change from uphill to downhill, or from downhill to uphill, in the progression specified
for any pass of a vertical weld, other than a wash (cover) pass (cosmetic pass).
16.2.9.6 A change from one welding process to any other welding process or combination of weld-
ing processes.
17.0 POSTWELD HEAT TREATMENT
17.1 General
17.1.1 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.
17.1.2 Minimum temperatures required by this section shall be temperatures of plate material of
shell and heads of the tank.
17.1.3 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.
17.1.4 Tank shell and head shall determine postweld heat treatment requirements, except as
allowed by Appendix R, paragraph 20.4.
10/2007 C-III [M-1002] 483

APPENDIX W M-1002
17.2 Procedures for Postweld Heat Treatment

17.2.1 The tank shall preferably be postweld heat treated as a unit in an enclosed furnace.
17.2.2 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.
17.3 Requirements for Postweld Heat Treatment
17.3.1 The furnace shall be designed to prevent direct flame impingement on the tank being
heated.
17.3.2 During the heating, holding, and cooling periods, the furnace atmosphere shall be con-
trolled to avoid excessive oxidation of the tank surface.
17.3.3 The temperature of the furnace shall not exceed 800 °F (427 °C) at the time the tank or
part is placed in it.
17.3.4 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 (5644 °C divided by tank thickness in millimeters), but in no case
more than 400 °F per hour (222 °C per hour).
17.3.5 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.
17.3.6 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.
17.3.7 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 (7055 °C
divided by the tank thickness in millimeters), but in no case more than 500 °F (278 °C) per hour.
Below 800 °F (427 °C), the tank may be cooled in still air or in a cooling chamber.
17.3.8 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 spe-
cific material.
17.4 Carbon Steel Tanks (Material Group 1)
Unless otherwise provided in the specifications for a tank, all tanks fabricated from materials in
Appendix M, Table M10.1, 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 min-
imum 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).
C-III [M-1002] 484 10/2007

M-1002 APPENDIX W
17.4.1 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 W17 may
be used.
Table W17. 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).
17.4.2 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.
17.4.3 Type 304L- or 316L-clad tanks shall not be heated to a temperature exceeding 1050 °F
(566 °C).
17.5 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 M10.6, shall be postweld heat treated as required for carbon steel tanks in
paragraph 17.4 above.
17.6 Manganese-Silicon Steel Tanks (Material Group 1)
17.6.1 Unless otherwise provided in the specifications for a tank, and except as required in
paragraph 17.6.2 below, all tanks fabricated from materials in Appendix M, Table M10.7, shall be
postweld heat treated as required for carbon steel tanks in paragraph 17.4 above.
17.6.2 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.
17.7 Nonferrous Metal Tanks (Material Groups 2, 4)
17.7.1 Tanks fabricated from aluminum and its alloys shall not be postweld heat treated.
17.7.2 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.
17.8 Nickel Alloy Steel Tanks (Material Group 7)
17.8.1 Unless otherwise provided in the specifications for a tank, all tanks fabricated from mate-
rials in Appendix M, Table M10.5, 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).
17.8.2 In lieu of the requirements of paragraph 17.3.7 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.
10/2007 C-III [M-1002] 485

APPENDIX W M-1002
17.9 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 M10.3:
17.9.1 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 M10.3. 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.
17.9.2 Types 304L and Type 316L. Tanks fabricated from these materials are not required to
be postweld heat treated.
18.0 QUALITY ASSURANCE
18.1 Quality Control Program
See the AAR Manual of Standards and Recommended Practices, Section J, Specification M-1003,
for quality assurance requirements.
19.0 RADIOGRAPHIC REQUIREMENTS
19.1 General
19.1.1 Unless otherwise provided in a tank specification, the requirements of this section shall
apply.
19.1.2 All rewelded (repaired) ares shall be radiographed as required by the inspector.
19.1.3 All required radiographic examinations shall be made using the technique and acceptance
standards of paragraph 11.2 above.
19.2 Weld Joints to be Radiographed
19.2.1 The entire length of the following double-welded butt joints shall be radiographed:
19.2.1.1 All longitudinal and circumferential joints of a tank, except circumferential joints in a
multi-unit tank car tank need not be radiographed.
19.2.1.2 The joint between the shell and certain types of fittings used to provide a reinforced
opening. See Appendix E, Fig. E20.2.
19.2.2 The entire length of a single-welded butt joint with backup shall be radiographed when it
is used, in combination with less than a full fillet weld, to attach the interior heads of compart-
ment tanks. See Appendix E.
19.2.3 For tanks constructed of Type 430A material, the radiography shall be performed after the
postweld heat treatment.
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M-1002 APPENDIX W
19.3 Radiography of Nonpressure Tanks Constructed in Groups

19.3.1 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 radio-
graphed in accord with paragraph 19.2.1 above, except as follows:
19.3.2 Weld Joint Category
19.3.2.1 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.
19.3.2.2 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.
19.3.3 If, in the first 3 tanks in the initial series of 20 tanks, there are no more than two unac-
ceptable defects in any radiographed circumferential joint, nor more than one unacceptable defect
in any 15-ft (4570-mm) radiographed longitudinal joint, then for the next 17 tanks, only the inter-
sections of the longitudinal and circumferential double-welded butt joints need be radiographed.
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.
19.3.4 Radiography of Intersections
19.3.4.1 A radiograph 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.
19.3.4.2 When a weld joint at an intersection contains an unacceptable defect, radiography of a
6-in. (152-mm) length of the weld joint in question, on each side of the defective weld area, is
required.
19.3.4.3 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 radiographed
until they are acceptable.
19.3.4.4 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 radiographed throughout their entire length. These three tanks shall be considered
the first of an initial series with respect to that category only, and the radiographic examination
procedure shall revert to that specified in paragraph 19.3.1 above.
19.3.5 Succeeding tanks
19.3.5.1 In each successive series of 20 tanks, only the intersections of the longitudinal and cir-
cumferential double-welded butt joints need be radiographed, except that one tank, selected at
random by the inspector, shall be radiographed in accordance with paragraph 19.2.1 above.
19.3.5.2 If there are no more than two unacceptable defects in any radiographed circumferential
joint, nor more than one unacceptable defect in any 15-ft (4570-mm) length of radiographed longi-
tudinal joint, then for the remaining tanks in the series, only the intersections of the longitudinal
and circumferential double-welded butt joints need be radiographed. 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.
19.3.5.3 If defects exceed those in paragraph 19.3.5.2 above, then the tank shall be treated as the
first in an initial series of 20 tanks, and the radiographic procedure shall revert to that specified in
paragraph 19.3.1 above.
10/2007 C-III [M-1002] 487

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
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. W4A when dissimilar materials
used permit longitudinal face- and
root-bend specimens.
SKETCH B: SUGGESTED ORDER OF REMOVAL OF SPECIMENS
Fig. W1 Test plate
C-III [M-1002] 488 10/2007

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
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. W4A when dissimilar materials
used permit longitudinal face- and
root-bend specimens.
SKETCH B: SUGGESTED ORDER OF REMOVAL OF SPECIMENS
Fig. W1.1 Test plate—SI units
10/2007 C-III [M-1002] 489

APPENDIX W M-1002
10'' approximately t
¼"
Edge of widest On ferrous material

W face of weld these edges may be
flame cut
¼"
Weld reinforcement shall
2'' R be machined flush with
W = 1 1/2'' ± 0.01'', if t base material
does not exceed 1''
¼" 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
A—reduced section length See Note 4 See Note 4 See Note 4 See Note 4
B—end section length 1 3/8 approx. 1 1/8 approx. 7/8 approx. 1/2 approx.
C—end section diameter 3/4 1/2 3/8 1/4
D—diameter 0.500 ± 0.010 0.350 ± 0.007 0.250 ± 0.005 0.188 ± 0.003
R—radius 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. W2 Joint-tension specimens
C-III [M-1002] 490 10/2007

M-1002 APPENDIX W
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
A—reduced section length See Note 4 See Note 4 See Note 4 See Note 4
B—end section length 35 approx. 29 approx. 22 approx. 13 approx.
C—end section diameter 19.0 12.7 9.52 6.35
D—diameter 12.45 to 12.95 8.72 to 9.06 6.23 to 6.47 4.70 to 4.85
R—radius 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. W2.1 Joint-tension specimens—SI units
10/2007 C-III [M-1002] 491

APPENDIX W M-1002
B A B
G
R WELD
D C
METAL
Standard Dimensions of Specimen (in.)

0.505 0.353 0.252
A—length of reduced section, min.a/ 2 1/4 1 3/4 1 1/4
B—length of end section, approx.b/ 1 3/8 1 1/8 7/8
C—diameter of end sectionb/ 3/4 1/2 3/8
D—diameter of reduced section 0.500 ± 0.010 0.350 ± 0.007 0.250 ± 0.005
G—gauge length 2.000 ± 0.005 1.400 ± 0.005 1.000 ± 0.005
L—overall length, approx.b/ 5 5 5
R—radius of fillet, min. 3/8 1/4 3/16
NOTES:
a/ If desired, the length of the reduced section may be increased to accommodate an extensometer of any convenient
gauge length. Reference marks for measurement of elongation should, nevertheless, be spaced at the indicated gauge
length, G. The gauge marks may be made with center punch, scribe, multiple device, or drawn with ink. They shall be
light, sharp, and accurately spaced.
b/ Other types of ends may be used, but should fit the holders of the testing machine in such a way that the load is
applied axially.
Fig. W3 All-weld-metal tension specimen
C-III [M-1002] 492 10/2007

M-1002 APPENDIX W
B A B
G
R WELD
D C
METAL
Standard Dimensions of Specimen (mm)

12.83 8.97 6.40
A—length of reduced section, min.a/ 57.2 44.4 31.8
B—length of end section, approx.b/ 35 29 22
C—diameter of end section b/ 19.0 12.7 9.52
D—diameter of reduced section 12.45 to 12.95 8.72 to 9.06 6.23 to 6.47
G—gauge length 50.68 to 50.92 35.44 to 35.68 25.28 to 25.52
L—overall length, approxb/ 127 127 127
R—radius of fillet, min. 9.82 6.38 4.76
NOTES:
a/ If desired, the length of the reduced section may be increased to accommodate an extensometer of any convenient
gauge length. Reference marks for measurement of elongation should, nevertheless, be spaced at the indicated gauge
length, G. The gauge marks may be made with center punch, scribe, multiple device, or drawn with ink. They shall be
light, sharp, and accurately spaced.
b/ Other types of ends may be used, but should fit the holders of the testing machine in such a way that the load is
applied axially.
Fig. W3.1 All-weld-metal tension specimen—SI units
10/2007 C-III [M-1002] 493

APPENDIX W M-1002
WELD
When all-weld-metal tension, impact, or
TENSION SPECIMEN
REDUCED-SECTION
TENSION SPECIMEN
REDUCED-SECTION
THIS
THIS
LONGITUDINAL
LONGITUDINAL
LONGITUDINAL
LONGITUDINAL
corrosion test specimens are required, provide
ROOT-BEND
ROOT-BEND
FACE-BEND
FACE-BEND
SPECIMEN
SPECIMEN
SPECIMEN
SPECIMEN
additional material as shown in Figs. W1A,
W21A, or W21B.
DISCARD
DISCARD
SKETCH A: SUGGESTED ORDER OF REMOVAL OF TEST SPECIMENS
FACE-BEND ROOT-BEND
R = 1/8 in. max
WELD T (in.)
1 ½"
t (in.) Materials in All Other
R R Table M10.2 Materials
T T 1/16–1/8 t t
6" MINIMUM
t t 1/8–3/8 1/8 t
Weld reinforcement and backing strip, if any, shall LF Over 3/8 1/8 3/8
LR
be removed flush with the surface of the specimen.
SKETCH B: LONGITUDINAL FACE-BEND AND LONGITUDINAL ROOT-BEND SPECIMENS
Fig. W4 Test plate and guided-bend test specimens for dissimilar metals
WELD
When all-weld-metal tension, impact, or

TENSION SPECIMEN
REDUCED-SECTION
TENSION SPECIMEN
REDUCED-SECTION
THIS
THIS
corrosion test specimens are required, provide

LONGITUDINAL
LONGITUDINAL
LONGITUDINAL
LONGITUDINAL
ROOT-BEND
ROOT-BEND
FACE-BEND
FACE-BEND
SPECIMEN
SPECIMEN
SPECIMEN
SPECIMEN
additional material as shown in Figs. W1A,

W21A, or W21B.
DISCARD
DISCARD
SKETCH A: SUGGESTED ORDER OF REMOVAL OF TEST SPECIMENS
FACE-BEND ROOT-BEND
R = 3.18 max
T (mm)
WELD 38.1
t (mm) Materials in All Other
R R Table M10.2 Materials
T T 1.59 to 3.18 t t
152 MINIMUM
t t 3.18 to 9.52 3.18 t
Weld reinforcement and backing strip, if any, shall Over 9.52 3.18 9.52
LF LR
be removed flush with the surface of the specimen.
SKETCH B: LONGITUDINAL FACE-BEND AND LONGITUDINAL ROOT-BEND SPECIMENS
Fig. W4.1 Test plate and guided-bend test specimens for dissimilar metals—SI units
C-III [M-1002] 494 10/2007
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 ½"
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. W4B.
Fig. W5 Guided-bend test specimens
10/2007 C-III [M-1002] 495

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. W4B.
Fig. W5.1 Guided-bend test specimens—SI units
C-III [M-1002] 496 10/2007

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. W6 Guided-bend test jig
10/2007 C-III [M-1002] 497

APPENDIX W M-1002
To determine SI
dimensions, see
Appendix H,
paragraph 5.3.5
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. W6.1 Guided-bend test jig—SI units
C-III [M-1002] 498 10/2007

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 = ¼"; CENTER
and maximum fillet size is ¼".
2. For nonferrous materials: 3"

L = 4"; L
W = 4";
T = 16" to 8 " ;
3 3
and maximum fillet size is the

same as dimension T. 1"
T W
SKETCH A: FOR PERFORMANCE QUALIFICATION TEST
MACRO TEST
12" MIN.
NOTES:
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. W7 Fillet-welded tee-joint test specimens
10/2007 C-III [M-1002] 499

APPENDIX W M-1002
MACRO TEST
NOTES: DIRECTION OF LOADING

1. For ferrous materials:
L = 254;
W = 76.2;
T = 6.35;
and maximum fillet size is 6.35. STOP AND RESTART
WELDING NEAR THE
2. For nonferrous materials: CENTER
L = 102;
W = 102;
T = 4.76 to 9.52; L
and maximum fillet size is the
same as dimension T.
SKETCH A: FOR PERFORMANCE QUALIFICATION TEST
MACRO TEST
NOTES:
T = MAXIMUM THICKNESS OF
BASE MATERIAL IN TANK AT POINT
OF WELDING OR 25.4, WHICHEVER IS
SMALLER.
FIVE EQUAL SECTION
DISCARD END SECTIONS
SKETCH B: FOR PROCEDURE QUALIFICATION TEST
Fig. W7.1 Fillet-welded tee-joint test specimens—SI units
C-III [M-1002] 500 10/2007

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
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 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. W8 Weld orientation and test positions—fillet welds
10/2007 C-III [M-1002] 501

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. W9 Weld orientation and test positions—groove welds
C-III [M-1002] 502 10/2007

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 ½" (12.7) AND
THINNER. IF OVER ½" (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. W10 Impact test specimen location and orientation
10/2007 C-III [M-1002] 503

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 μ (63 microinches AA) on notched surface and
(AA = arithmetical average) opposite face; 4 μ (125 microinches AA) on
other two surfaces.
Fig. W11 Type A Charpy (simple beam) impact test specimen dimensions
C-III [M-1002] 504 10/2007

M-1002 APPENDIX W
Suggested Format for Welding Procedure Specification (WPS)

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. W12 Suggested format for welding procedure specification (WPS)
10/2007 C-III [M-1002] 505
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. W12 Suggested format for welding procedure specification (WPS) (continued)
C-III [M-1002] 506 10/2007
M-1002 APPENDIX W
Suggested Format for Procedure Qualification Record (PQR)

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 __________________________________________ ________________________________________________
________________________________________________ ________________________________________________
Revised 3/16/88Page 1 of 2
Fig. W13 Suggested format for procedure qualification record (PQR)
10/2007 C-III [M-1002] 507

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
ALL—WELD—METAL 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 _________________________________________________________________________________________________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Welder’s 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. W13 Suggested format for procedure qualification record (PQR) (continued)
C-III [M-1002] 508 10/2007
M-1002 APPENDIX W
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
Q Manual or Semiautomatic Variables for Each Process (W12.4) 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Q Machine Welding Variables for the Process Used (W12.2)
Guided Bend Test Results
Guided Bend Tests Type ( ) Fig W5C (Side) ( ) Fig W5A&B (Trans. R & F) ( ) Fig W5B (Long, R & F)
Type (Side, Root, Face) Result Type (Side, Root, Face) Result
Visual examination results
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. x 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. W14 Record of Welder Performance Qualification Test

10/2007 C-III [M-1002] 509
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. W15 Positions of test plates for butt welds (joint design optional)
C-III [M-1002] 510 10/2007

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. W16 Positions of test plates for fillet welds
10/2007 C-III [M-1002] 511

APPENDIX W M-1002
Dimension, inches No. of Pores
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 PORE AREA PERMITTED IS 0.030 SQ IN.
Fig. W17 Porosity charts
C-III [M-1002] 512 10/2007

M-1002 APPENDIX W
Dimension, millimeters No. of Pores
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 PORE AREA PERMITTED IS 19.4 SQ. MM.
Fig. W17.1 Porosity charts—SI units
10/2007 C-III [M-1002] 513

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 PORE AREA PERMITTED IS .045 SQ. IN.
C-III [M-1002] 514 10/2007

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. W18.1 Porosity charts
10/2007 C-III [M-1002] 515

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 PORE AREA PERMITTED IS 0.060 SQ. IN.
C-III [M-1002] 516 10/2007

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

10/2007 C-III [M-1002] 517

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 PORE AREA PERMITTED IS .120 SQ. IN.
C-III [M-1002] 518 10/2007

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

10/2007 C-III [M-1002] 519

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. W1B FOR DETAILS SEE FIG. W1B
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. W21 Order of removal of test specimens
C-III [M-1002] 520 10/2007

M-1002 APPENDIX W
Fig. W22 Welding symbols

10/2007 C-III [M-1002] 521
APPENDIX W M-1002
Fig. W22.1 Welding symbols

C-III [M-1002] 522 10/2007
M-1002 APPENDIX W
FACE-BEND SPECIMEN
DIRECTION
FACE-BEND SPECIMEN
OF
WELDING
FACE-BEND SPECIMEN 1 ½" (TYP.)
FACE-BEND SPECIMEN
MICRO-HARDNESS
SECTION
½"
(SEE NOTE)
1 ½" MIN.
WELD 1 ½"
OVERLAY
BACK SIDE
NOTE: THE BACK SIDE OF THESE COUPONS MAY NEED TO BE MACHINED

TO THE ½" FACE-BEND THICKNESS
Fig. W23 Order of removal for face bends for weld overlay procedure qualification
10/2007 C-III [M-1002] 523

APPENDIX W M-1002
Fig. W24 Detail for microhardness sections for weld overlay procedure qualification
C-III [M-1002] 524 10/2007

M-1002 APPENDIX X
APPENDIX X
DOT REGULATIONS
CONTENTS
Paragraph Subject Page No.

1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–526
Sec.173.31 Use of Tank Cars—General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–527
Sec.173.314 Compressed Gases in Tank Cars and Multi-Unit Tank Car Tanks . . . . . . . . . . . . . . . . . . C-III–530
Sec.173.319 Cryogenic Liquids in Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–532
Sec.173.320 Cryogenic Liquids:Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–533
Part 179 Specifications for Tank Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–534
Subpart A—Introduction, Approvals and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–534
Subpart B—General Design Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–536
Subpart C—Specifications for Pressure Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . . . . . C-III–537
Subpart D—Specifications for Nonpressure Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . . C-III–542
Subpart E—Specifications for Multi-Unit Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . C-III–550
Subpart F—Specifications for Cryogenic Liquid Tank Car Tanks and Seamless Steel
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–552
Appendices to Part 179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–559
DOT Notice 93-12 Excepted Thermal Protection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–561
10/2007 C-III [M-1002] 525

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 180.500. For the convenience of the
reader, these sections, with the exception of Part 180.500, which is shown in Appendix D,
paragraph 2.0 of this specification, are reproduced from Bureau of Explosives Tariff No.BOE6000-
AA in effect August 29, 2007.
Also included in this Appendix is DOT’s current 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] 526 10/2007

M-1002 APPENDIX X
§173.28—§173.31 July 2007
this subchapter as a manufacturer. vehicle or vessel in conformance with the applicable loading and un-
(e) Non-reusable containers. A packaging marked as NRC ac- loading requirements of parts 174, 175, 176, and 177 of this subchapter.
cording to the DOT specification or UN standard requirements of part
178 of this subchapter may be reused for the shipment of any material §173.31@Use of tank cars. (a) General. (1) No person may offer
not required by this subchapter to be shipped in a DOT specification a hazardous material for transportation in a tank car unless the tank
or UN standard packaging. car meets the applicable specification and packaging requirements
(f) A Division 6.2 packaging to be reused must be disinfected of this subchapter or, when this subchapter authorizes the use of an
prior to reuse by any means effective for neutralizing the infectious non-DOT specification tank car, the applicable specification to which
substance the packaging previously contained. A secondary packag- the tank was constructed.
ing or outer packaging conforming to the requirements of §173.196 (2) Tank cars and appurtenances may be used for the transporta-
or §173.199 need not be disinfected prior to reuse if no leakage from tion of any commodity for which they are authorized in this part and
the primary receptacle has occurred. specified on the certificate of construction (AAR Form 4-2 or by adden-
dum on Form R-1). See §179.5 of this subchapter. Transfer of a tank
§173.29@Empty packagings. (a) General. Except as otherwise car from one specified service on its certificate of construction to
provided in this section, an empty packaging containing only the another may be made only by the owner or with the owner’s authoriza-
residue of a hazardous material shall be offered for transportation and tion. A tank car proposed for a commodity service other than specified
transported in the same manner as when it previously contained a on its certificate of construction must be approved for such service
greater quantity of that hazardous material. by the AAR’s Tank Car Committee.
(b) Notwithstanding the requirements of paragraph (a) of this sec- (3) No person may fill a tank car overdue for periodic inspection with
tion, an empty packaging is not subject to any other requirements of a hazardous material and then offer it for transportation. Any tank car
this subchapter if it conforms to the following provisions: marked as meeting a DOT specification and any non-specification tank
(1) Any hazardous material shipping name and identification num- car transporting a hazardous material must have a periodic inspection
ber markings, any hazard warning labels or placards, and any other and test conforming to subpart F of part 180 of this subchapter.
markings indicating that the material is hazardous (e.g., RQ, INHALA- (4) No railroad tank car, regardless of its construction date, may
TION HAZARD) are removed, obliterated, or securely covered in trans- be used for the transportation in commerce of any hazardous material
portation. This provision does not apply to transportation in a transport unless the air brake equipment support attachments of such tank car
vehicle or a freight container if the packaging is not visible in transpor- conform to the standards for attachments set forth in §§179.100-16
tation and the packaging is loaded by the shipper and unloaded by and 179.200-19 of this subchapter.
the shipper or consignee; (5) No railroad tank car, regardless of its construction date, may be
(2) The packaging— used for the transportation in commerce of any hazardous material with
a self-energized manway located below the liquid level of the lading.
(i) Is unused;
(6) Unless otherwise specifically provided in this part:
(ii) Is sufficiently cleaned of residue and purged of vapors to re-
(i) When the tank car delimiter is an “A,” offerors may also use
move any potential hazard;
tank cars with a delimiter “S,” “J” or “T”.
(iii) Is refilled with a material which is not hazardous to such an (ii) When the tank car delimiter is an “S,” offerors may also use
extent that any residue remaining in the packaging no longer tank cars with a delimiter “J” or “T”.
poses a hazard; or (iii) When a tank car delimiter is a “T” offerors may also use tank
(iv) Contains only the residue of— cars with a delimiter of “J”.
(A) An ORM-D material; or (iv) When a tank car delimiter is a “J”, offerors may not use a tank
(B) A Division 2.2 non-flammable gas, other than ammonia, car with any other delimiter.
anhydrous, and with no subsidiary hazard, at an absolute (7) A class DOT–103 or DOT–104 tank car may continue to be
pressure less than 280 kPa (40.6 psia); at 20°C (68°F); and used for the transportation of a hazardous material if it meets the
(3) Any material contained in the packaging does not meet the requirements of this subchapter and the design requirements in Part
definitions in §171.8 of this subchapter for a hazardous substance, a 179 of this subchapter in effect on September 30, 2003; however, no
hazardous waste, or a marine pollutant. new construction is authorized.
(c) A non-bulk packaging containing only the residue of a hazard- (8) A tank car authorized by the Transport Canada TDG Regulations ★
ous material covered by Table 2 of §172.504 of this subchapter that (IBR, see §171.7 of this subchapter) may be used provided it conforms
is not a material poisonous by inhalation or its residue shipped under to the applicable requirements in §171.12 of this subchapter.
the subsidiary placarding provisions of §172.505— (b) Safety systems—(1) Coupler vertical restraint. Each tank car
(1) Does not have to be included in determining the applicability conforming to a DOT specification and any other tank car used for
of the placarding requirements of subpart F of part 172 of this subchap- transportation of a hazardous material must be equipped with a cou-
ter; and pler vertical restraint system that meets the requirements of §179.14
(2) Is not subject to the shipping paper requirements of this sub- of this subchapter.
chapter when collected and transported by a contract or private carrier (2) Pressure relief devices. (i) Pressure relief devices on tank cars
for reconditioning, remanufacture or reuse. must conform to part 179 of this subchapter.
(d) Notwithstanding the stowage requirements in Column 10A of (ii) A single-unit tank car transporting a Division 6.1 PG I or II, or
the §172.101 table for transportation by vessel, an empty drum or Class 2, 3, or 4 material must have a reclosing pressure relief
cylinder may be stowed on deck or under deck. device. However, a single-unit tank car built before January 1,
(e) Specific provisions for describing an empty packaging on a 1991, and equipped with a non-reclosing pressure relief device
shipping paper appear in §172.203(e) of this subchapter. may be used to transport a Division 6.1 PG I or II material or
(f) [Reserved] a Class 4 liquid provided such materials do not meet the defini-
(g) A package which contains a residue of an elevated temperature tion of a material poisonous by inhalation.
material may remain marked in the same manner as when it contained (3) Tank-head puncture-resistance requirements. The following
a greater quanitity of the material even though it no longer meets the tank cars must have a tank-head puncture-resistance system that
definition in §171.8 of this subchapter for an elevated temperature ma- conforms to the requirements in §179.16 of this subchapter, or to the
terial. corresponding requirements in effect at the time of installation:
(h) A package that contains a residue of a hazardous substance, (i) Tank cars transporting a Class 2 material.
Class 9, listed in the §172.101 Table, Appendix A, Table I, that does (ii) Tank cars constructed from aluminum or nickel plate that are
not meet the definition of another hazard class and is not a hazardous used to transport hazardous material.
waste or marine pollutant, may remain marked, labeled and, if applica- (iii) Except as provided in paragraph (b)(3)(iv) of this section, those
ble, placarded in the same manner as when it contained a greater tank cars specified in paragraphs (b)(3)(i) and (ii) of this section
quantity of the material even though it no longer meets the definition not requiring a tank-head puncture resistance system prior to
in §171.8 of this subchapter for a hazardous substance. July 1, 1996, must have a tank-head puncture resistance system
installed no later than July 1, 2006.
§173.30@Loading and unloading of transport vehicles. A person (iv) Class DOT 105A tank cars built prior to September 1, 1981,
who is subject to the loading and unloading regulations in this subchap- having a tank capacity less than 70 kl (18,500 gallons), and
ter must load or unload hazardous materials into or from a transport used to transport a Division 2.1 (flammable gas) material, must
292
10/2007 C-III [M-1002] 527

APPENDIX X M-1002
April 2007 (7/07) §173.31
have a tank-head puncture-resistant system installed no later (i) Except where insulation or a thermal protection system pre-
than July 1, 2001. cludes an inspection, the tank shell and heads for abrasion, cor-
(4) Thermal protection requirements. The following tank cars rosion, cracks, dents, distortions, defects in welds, or any other
must have thermal protection that conforms to the requirements of condition that makes the tank car unsafe for transportation;
§179.18 of this subchapter. (ii) The piping, valves, fittings, and gaskets for corrosion, damage,
(i) Tank cars transporting a Class 2 material, except for a class or any other condition that makes the tank car unsafe for transpor-
106, 107A, 110, and 113 tank car. A tank car equipped with tation;
a thermal protection system conforming to §179.18 of this sub- (iii) For missing or loose bolts, nuts, or elements that make the tank
chapter, or that has an insulation system having an overall car unsafe for transportation;
thermal conductance of no more than 0.613 kilojoules per hour, (iv) All closures on tank cars and determine that the closures and all
per square meter, per degree Celsius temperature differential fastenings securing them are properly tightened in place by the
(0.03 B.t.u. per square foot, per hour, per degree Fahrenheit use of a bar, wrench, or other suitable tool;
temperature differential), conforms to this requirement. (v) Protective housings for proper securement;
(ii) A tank car transporting a Class 2 material that was not required (vi) The pressure relief device, including a careful inspection of the
to have thermal protection prior to July 1, 1996, must be rupture disc in non-reclosing pressure relief devices, for corro-
equipped with thermal protection no later than July 1, 2006. sion or damage that may alter the intended operation of the
(5) Bottom-discontinuity protection requirements. No person device;
may offer for transportation a hazardous material in a tank car with (vii) Each tell-tale indicator after filling and prior to transportation to
bottom-discontinuity protection unless the tank car has bottom- ensure the integrity of the rupture disc;
discontinuity protection that conforms to the requirements of E9.00 (viii) The external thermal protection system, tank-head puncture re-
and E10.00 of the AAR Specifications for Tank Cars (IBR, see §171.7 sistance system, coupler vertical restraint system, and bottom
of this subchapter). Tank cars not requiring bottom-discontinuity discontinuity protection for conditions that make the tank car un-
protection under the terms of appendix Y of the AAR Specifications safe for transportation;
for Tank Cars as of July 1, 1996, must conform to these requirements (ix) The required markings on the tank car for legibility; and
no later than July 1, 2006, except that tank cars transporting a (x) The periodic inspection date markings to ensure that the inspec-
material that is hazardous only because it meets the definition of tion and test intervals are within the prescribed intervals.
an elevated temperature material or because it is molten sulfur do (2) Closures on tank cars are required, in accordance with this sub-
not require bottom discontinuity protection. Tank cars modified chapter, to be designed and closed so that under conditions normally
before July 1, 1996, may conform to the bottom-discontinuity protec- incident to transportation, including the effects of temperature and vi-
tion requirements of appendix Y, instead of paragraphs E9.00 or bration, there will be no identifiable release of a hazardous material to
E10.00 of the AAR Specifications for Tank Cars. the environment. ln any action brought to enforce this section, the lack
(6) Scheduling of modifications and progress reporting. The of securement of any closure to a tool-tight condition, detected at any
date of conformance for the continued use of tank cars subject to point, will establish a rebuttable presumption that a proper inspection
paragraphs (b)(3), (b)(4), (b)(5), (e)(2), and (f) of this section and was not performed by the offeror of the car. That presumption may be
§§173.314(j) and 173.323(c)(1) is subject to the following conditions rebutted by any evidence indicating that the lack of securement resulted
and limitations. from a specific cause not within the control of the offeror.
(i) Each tank car owner shall modify, reassign, retire, or remove (e) Special requirements for materials poisonous by inha-
at least 50 percent of their in-service tank car fleet within the lation—
first half of the compliance period and the remainder of their in- (1) Interior heater coils. Tank cars used for materials poisonous
service tank car fleet during the second half of the compliance by inhalation may not have interior heater coils.
period. (2) Tank car specifications. A tank car used for a material poisonous
(ii) By October 1 of each year, each owner of a tank car subject by inhalation must have a tank test pressure of 20.7 Bar (300 psig)
to this paragraph (b)(6) shall submit to the Federal Railroad or greater, head protection, and a metal jacket (e.g., DOT 105S300W),
Administration, Hazardous Materials Division, Office of Safety except that—
Assurance and Compliance, 1120 Vermont Avenue, Mail Stop (i) A higher test pressure is required if otherwise specified in this
25, Washington, DC 20590,aprogress report that shows the subchapter; and
total number of in-service tank cars that need head protection, (ii) Other than as provided in paragraph (b)(6) of this section, a
thermal protection, or bottom-discontinuity protection; the num- tank car which does not conform to the requirements of this
ber of new or different tank cars acquired to replace those tank paragraph (e)(2), and was authorized for the material poisonous
cars required to be upgraded to a higher service pressure; and by inhalation under the regulations in effect on June 30, 1996,
the total number of tank cars modified, reassigned, acquired, may continue in use until July 1, 2006.
retired, or removed from service the previous year. (f) Special requirements for hazardous substances. (1) A tank
(c) Tank car test pressure. A tank car used for the transportation car used for a hazardous substance listed in paragraph (f)(2) of this
of a hazardous material must have a tank test pressure equal to or section must have a tank test pressure of at least 13.8 Bar (200 psig),
greater than the greatest of the following: head protection and a metal jacket, except that—
(1) Except for shipments of carbon dioxide, anhydrous hydrogen (i) No metal jacket is required if—
chloride, vinyl fluoride, ethylene, or hydrogen, 133 percent of the sum (A) The tank test pressure is 23.4 Bar (340 psig) or higher; or
of lading vapor pressure at the reference temperature of 46°C (115°F) (B) The tank shell and heads are manufactured from AAR
for non-insulated tank cars or 41°C (105°F) for insulated tank cars steel specification TC-128, normalized;
plus static head, plus gas padding pressure in the vacant space of (ii) A higher test pressure is required if otherwise specified in this
a tank car; subchapter; and
(2) 133 percent of the maximum loading or unloading pressure, (iii) Other than as provided in paragraph (b)(6) of this section, a
whichever is greater; tank car which does not conform to the requirements of this
(3) 20.7 Bar (300 psig) for materials that are poisonous by inhalation paragraph (f)(1), and was authorized for a hazardous sub-
(see §173.31(e)(2)(ii) for compliance dates); stance under the regulations in effect on June 30, 1996, may
(4) The minimum pressure prescribed by the specification in part continue in use until July 1, 2006.
179 of this subchapter; or (2) List of hazardous substances. Hazardous substances for
(5) The minimum test pressure prescribed for the specific hazard- which the provisions of this paragraph (f) apply are as follows:
ous material in the applicable packaging section in subpart F or G Aldrin
of this part. Allyl chloride
(d) Examination before shipping. (1) No person may offer for alpha-BHC
transportation a tank car containing a hazardous material or a residue beta-BHC
of a hazardous material unless that person determines that the tank delta-BHC
car is in proper condition and safe for transportation. As a minimum, gamma-BHC
each person offering a tank car for transportation must perform an Bis(2-chloroethyl) ether
external visual inspection that includes: Bromoform
293
C-III [M-1002] 528 10/2007

M-1002 APPENDIX X
§173.31—§173.32 July 2007
Carbon tetrachloride (2) Caution signs must be placed between the rails to give neces-
Chlordane sary warning to persons approaching the car(s) from the open end
p-Chloroaniline of a siding and must be left up until after all closures are secured and
Chlorobenzene the cars are in proper condition for transportation. The signs must be
Chlorobenzilate of a durable material, blue in color, rectangular in shape, at least
p-Chloro-m-cresol 30.48 cm (12 inches) high by 38.10 cm (15 inches) wide, and bear
2-Chlorethyl vinyl ether the word “STOP.” The word “STOP” must appear in white letters at
Chloroform least 10.16 cm (4 inches) high. Additional words, such as “Tank Car
2-Chloronapthalene Connected” or “Crew at Work,” may also appear in white letters under
o-Chlorophenol the word “STOP.”
3-Chloropropionitrile (3) At least one wheel on the tank car must be blocked against
DDE movement in both directions, and the hand brakes must be set. If
DDT multiple tank cars are coupled together, sufficient hand brakes must
1,2-Dibromo-3-chloropropane be set and wheels blocked to prevent movement in both directions.
m-Dichlorobenzene
§173.32@Requirements for the use of portable tanks.
o-Dichlorobenzene
(a) General requirements. No person may offer a hazardous mate-
p-Dichlorobenzene
rial for transportation in a portable tank except as authorized by this
3,3′-Dichlorobenzidine
subchapter.
1,4-Dichloro-2-butene
(1) Except as otherwise provided in this subpart, no person may
1,1-Dichloroethane
use a portable tank for the transportation of a hazardous material
1,2-Dichloroethane
unless it meets the requirements of this subchapter.
1,1-Dichloroethylene
(2) No person may fill and offer for transportation a portable tank
Dichloroisopropyl ether
when the prescribed periodic test or inspection under subpart G of
Dichloromethane @
part 180 of this subchapter has become due until the test or inspection
2,4-Dichlorophenol
has been successfully completed. This requirement does not apply
2,6-Dichlorophenol
to any portable tank filled prior to the test or inspection due date.
1,2-Dichloropropane
(3) When a portable tank is used as a cargo tank motor vehicle, it
1,3-Dichloropropene
must conform to all the requirements prescribed for cargo tank motor
Dieldrin
vehicles. (See §173.33.)
alpha-Endosulfan
(b) Substitute packagings. A particular Specification portable
beta-Endosulfan
tank may be substituted for another portable tank as follows:
Endrin
Endrin aldehyde (1) An IM or UN portable tank may be used whenever an IM or
UN portable tank having less stringent requirements is authorized
Heptachlor
provided the portable tank meets or exceeds the requirements for
Heptachlor epoxide
pressure-relief devices, bottom outlets and any other special provi-
Hexachlorobenzene
sions specified in §172.102(c)(7)(vi) of this subchapter.
Hexachlorobutadiene
(2) Where a Specification IM101 or IM102 portable tank is pre-
Hexachloroethane
scribed, a UN portable tank or Specification 51 portable tank otherwise
Hexachlorophene
conforming to the special commodity requirements of §172.102(c)(7)
Hexachloropropene
of this subchapter for the material to be transported may be used.
Isodrin
(3) A DOT Specification 51 portable tank may be used whenever
Kepone
a DOT Specification 56, 57, or 60 portable tank is authorized. A DOT
Methoxychlor
Specification 60 portable tank may be used whenever a DOT Specifi-
4,4′-Methylenebis(2-chloroaniline)
cation 56 or 57 portable tank is authorized. A higher integrity tank
Methylene bromide
used instead of a specified portable tank must meet the same design
Pentachlorobenzene profile; for example, a DOT Specification 51 portable tank must be
Pentachloroethane lined if used instead of a lined DOT Specification 60 portable tank.
Pentachloronitrobenzene (PCNB) ★
(4) A portable tank authorized by the Transport Canada TDG Regu-
Pentachlorophenol
lations (IBR, see §171.7 of this subchapter) may be used provided it
Polychlorinated biphenyls (PCBs) conforms to the applicable requirements in §171.12 of this subchapter.
Pronamide
(c) Grandfather provisions for portable tanks—(1) Continued
Silvex (2,4,5-TP)
use of Specification 56 and 57 portable tanks. Continued use of an
2,4,5-T existing portable tank constructed to DOT Specification 56 or 57 is au-
TDE thorized only for a portable tank constructed before October 1, 1996.
1,2,4,5-Tetrachlorobenzene A stainless steel portable tank internally lined with polyethylene that was
2,3,7,8-Tetrachlorodibenzo-p-dioxin (TCDD) constructed on or before October 1, 1996, and that meets all require-
Tetrachloroethane ments of DOT Specification 57 except for being equipped with a
Tetrachloroethylene polypropylene discharge ball valve and polypropylene secondary dis-
2,3,4,6-Tetrachlorophenol charge opening closure, may be marked as a Specification 57 portable
Toxaphene tank and used in accordance with the provisions of this section.
1,2,4-Trichlorobenzene (2) A DOT Specification 51, IM 101, or IM 102 portable tank may not
1,1,1-Trichloroethane be manufactured after January 1, 2003; however, such tanks may con-
1,1,2-Trichloroethane tinue to be used for the transportation of a hazardous material provided
Trichloroethylene they meet the requirements of this subchapter, including the specifica-
2,4,5-Trichlorophenol tion requirements and the requirements of this subchapter for the
2,4,6-Trichlorophenol transportation of the particular hazardous material according to the
Tris(2,3-dibromopropyl) phosphate T codes in effect on September 30, 2001 or the new T codes in
(g) Tank car loading and unloading. When placed for loading or §172.102(c)(7)(i) (see §171.14(d)(4) for transitional provisions appli-
unloading and before unsecuring any closure, a tank car must be cable to T codes), and provided the portable tank conforms to the
protected against movement or coupling as follows: periodic inspection and tests specified for the particular portable tank
(1) The unloader must secure access to the track to prevent entry in subpart G of part 180 of this subchapter. After January 1, 2003, all
by other rail equipment, including motorized service vehicles. Derails, newly manufactured portable tanks must conform to the requirements
lined and blocked switches, portable bumper blocks, or other equip- for the design, construction and approval of UN portable tanks as
ment that provides an equivalent level of security may be used to specified in §§178.273, 178.274, 178.275, 178.276, 178.277 and part
satisfy this requirement. 180, subpart G, of this subchapter.
294
10/2007 C-III [M-1002] 529

APPENDIX X M-1002
§173.313—§173.314 April 2007 (7/07)
UN PORTABLE TANK TABLE FOR LIQUIFIED COMPRESSED GASES
Minimum design
pressure Openings below Pressure relief require- Maximum filling
UN No. Non-refrigerated liquefied compressed gases
(bar) small; bare; liquid level ments (see §178.276(e)) density (kg/l)
sunshield; insulated
3318 Ammonia solution, relative density less than 0.880 at 15 °C See MAWP definition in Allowed §178.276(e)(3) §173.32(f)
in water, with more than 50% ammonia §178.276(a)
3337 Refrigerant gas R 404A 31.6; 28.3; 25.3; 22.5 Allowed Normal 0.84
3338 Refrigerant gas R 407A 31.3; 28.1; 25.1; 22.4 Allowed Normal 0.95
3339 Refrigerant gas R 407B 33.0; 29.6; 26.5; 23.6 Allowed Normal 0.95
3340 Refrigerant gas R 407C 29.9; 26.8; 23.9; 21.3 Allowed Normal 0.95
§173.314@Compressed gases in tank cars and multi-unit tank car (4) Wherever the word “approved” is used in this part of the regula-
tanks. (a) Definitions. For definitions of compressed gases, see tions, it means approval by the Association of American Railroads
§173.115. Committee on Tank Cars as prescribed in §179.3 of this subchapter.
(5) Each tank car used for the transportation of anhydrous ammonia
(b) General requirements. or any material that meets the criteria of Division 2.1 or 2.3 must have
(1) Tank car tanks containing compressed gases must not be gaskets for manway cover plates and for mounting of fittings designed
shipped unless they were loaded by or with the consent of the owner (for temperature, application, media, pressure, and size) to create a
thereof. positive seal so that, under conditions normally incident to transporta-
tion, there will not be an identifiable release of the material to the
(2) Tank car tanks must not contain gases capable of combining
environment. The use of sealants to install gaskets is prohibited.
chemically and must not be loaded with any gas which combines
(c) Authorized gases, filling limits for tank cars. A compressed
chemically with the gas previously loaded therein, until all residue has gas in a tank car or a multi-unit tank car must be offered for transporta-
been removed and interior of tank thoroughly cleaned. tion in accordance with §173.31 and this section. The named gases
(3) For tanks of the DOT-106A and 110A class, the tanks must be must be loaded and offered for transportation in accordance with the
placed in position and attached to car structure by the shipper. following table:
Proper shipping name Outage and filling limits (see note 1) Authorized tank car class
Ammonia, anhydrous, or ammonia solutions > 50 percent ammonia Notes 2, 10 105, 112, 114, 120.
Note 3 106.
Ammonia solutions with > 35 percent, but ≤ 50 percent ammonia by mass Note 3 105, 109, 112, 114, 120.
Argon, compressed Note 4 107.
Boron trichloride Note 3 105, 106.
Carbon dioxide, refrigerated liquid Note 5 105.
Chlorine Note 6 105.
125 106.
Chlorine trifluoride Note 3 106, 110.
Chlorine pentafluoride Note 3 106, 110.
Dimethyl ether Note 3 105, 106, 110, 112, 114, 120.
Dimethylamine, anhydrous Note 3 105, 106, 112.
Dinitrogen tetroxide, inhibited Note 3 105, 106, 110.
Division 2.1 materials not specifically identified in this table Notes 9, 10 105, 106, 110, 112, 114, 120.
Division 2.2 materials not specifically identified in this table Note 3 105, 106, 109, 110, 112, 114, 120.
Division 2.3 Zone A materials not specifically identified in this table. None See §173.245.
Division 2.3 Zone B materials not specifically identified in this table. Note 3 105, 106, 110, 112, 114, 120.
Division 2.3 Zone C materials not specifically identified in this table. Note 3 105, 106, 110, 112, 114, 120.
Division 2.3 Zone D materials not specifically identified in this table. Note 3 105, 106, 109, 110, 112, 114, 120.
Ethylamine Note 3 105, 106, 110, 112, 114, 120.
Helium, compressed Note 4 107.
Hydrogen Note 4 107.
Hydrogen chloride, refrigerated liquid Note 7 105.
Hydrogen sulphide, liquified 68 106.
Methyl bromide Note 3 105, 106.
Methyl chloride Note 3 105, 106, 112.
Methyl mercaptan Note 3 105, 106.
Methylamine, anhydrous Note 3 105, 106, 112.
Nitrogen, compressed Note 4 107.
Nitrosyl chloride 124 105.
110 106.
Nitrous oxide, refrigerated liquid Note 5 105.
Oxygen, compressed Note 4 107.
Phosgene Note 3 106.
Sulfur dioxide, liquified 125 105, 106, 110.
Sulfuryl fluoride 120 105.
Vinyl fluoride, stabilized Note 8 105.
374
C-III [M-1002] 530 10/2007

M-1002 APPENDIX X
April 2007 (7/07) §173.314—§173.315
Notes:
1. The percent filling density for liquefied gases is hereby defined as the percent ratio of the mass of gas in the tank to the mass of water that the tank will hold. For determining the
water capacity of the tank in kilograms, the mass of one L of water at 15.5°C in air is 1 kg. (the mass of one gallon of water at 60°F in air is 8.32828 pounds).
2. The liquefied gas must be loaded so that the outage is at least two percent of the total capacity of the tank at the reference temperature of 46°C (115°F) for a noninsulated tank; 43°C
(110°F) for a tank having a thermal protection system incorporating a metal jacket that provides an overall thermal conductance at 15.5°C (60°F) of no more than 10.22 kilojoules per hour
per square meter per degree Celsius (0.5 Btu per hour/per square foot/per degree F) temperature differential; and 41°C (105°F) for an insulated tank having an insulation system incorporating
a metal jacket that provides an overall thermal conductance at 15.5°C (60°F) of no more than 1.5333 kilojoules per hour per square meter per degree Celsius (0.075 Btu per hour/per
square foot/per degree F) temperature differential.
3. The requirements of §173.24b(a) apply.
4. The gas pressure at 54.44°C (130°F.) in any non-insulated tank car may not exceed 7/10 of the marked test pressure, except that a tank may be charged with helium to a pressure
10 percent in excess of the marked maximum gas pressure at 54.44°C (130°F.) of each tank.
5. The liquid portion of the gas at −17.77°C (0°F.) must not completely fill the tank.
6. The maximum permitted filling density is 125 percent. The quantity of chlorine loaded into a single unit-tank car may not be loaded in excess of the normal lading weights nor in
excess of 81.65 Mg (90 tons).
7. 89 percent maximum to 80.1 percent minimum at a test pressure of 6.2 Bar (90 psig).
8. 59.6 percent maximum to 53.6 percent minimum at a test pressure of 7.2 Bar (105 psig).
9. For a liquefied petroleum gas, the liquefied gas must be loaded so that the outage is at least one percent of the total capacity of the tank at the reference temperature of 46°C (115°F)
for a noninsulated tank; 43°C (110°F) for a tank having a thermal protection system incorporating a metal jacket that provides an overall thermal conductance at 15.5°C (60°F) of no more
than 10.22 kilojoules per hour per square meter per degree Celsius (0.5 Btu per hour/per square foot/per degree F) temperature differential; and 41°C (105°F) for an insulated tank having
an insulation system incorporating a metal jacket that provides an overall thermal conductance at 15.5°C (60°F) of no more than 1.5333 kilojoules per hour per square meter per degree
Celsius (0.075 Btu per hour/per square foot/per degree F) temperature differential.
10. For liquefied petroleum gas and anhydrous ammonia, during the months of November through March (winter), the following reference temperatures may be used: 38°C (100°F) for
a noninsulated tank; 32°C (90°F) for a tank having a thermal protection system incorporating a metal jacket that provides an overall thermal conductance at 15.5°C (60°F) of no more than
10.22 kilojoules per hour per square meter per degree Celsius (0.5 Btu per hour/per square foot/per degree F) temperature differential; and 29°C (85°F) for an insulated tank having an
insulation system incorporating a metal jacket and insulation that provides an overall thermal conductance at 15.5°C (60°F) of no more than 1.5333 kilojoules per hour per square meter
per degree Celsius (0.075 Btu per hour/per square foot/per degree F) temperature differential. The winter reference temperatures may only be used for a tank car shipped directly to a
consumer for unloading and not stored in transit. The offeror of the tank must inform each customer that the tank car was filled based on winter reference temperatures. The tank must be
unloaded as soon as possible after March in order to retain the specified outage and to prevent a release of hazardous material which might occur due to the tank car becoming liquid
full at higher temperatures.
(d) [Reserved]. specification.

(e) Verification of content. The amount of liquefied gas loaded into (l) Special requirements for hydrogen sulphide. Each multi-unit
each tank may be determined either by measurement or calculation of tank car must be equipped with adequate pressure relief devices of
the weight. If by measurement, the weight must be checked after the fusible plug type having a yield temperature not over 76.66°C
disconnecting the loading line by the use of proper scales. If by (170°F), and not less than 69.44°C (157°F). Each device must be
calculation, the weight of liquefied petroleum gas, methylacetylene resistant to extrusion of the fusible alloy and leak tight at 55°C (130°F).
propadiene, stabilized, dimethylamine, methylamine anhydrous, or A threaded solid plug must seal each valve outlet. In addition, a metal
trimethylamine may be calculated using the outage tables supplied cover must protect all valves.
by the tank car owners and the specific gravities as determined at (m) Special requirements for nitrosyl chloride. Single unit tank
the plant, and this computation must be checked by determination of cars and their associated service equipment, such as venting, loading
specific gravity of product after loading. Carriers may verify calculated and unloading valves, and reclosing pressure valves, must be made
weights by use of proper scales. The use of a fixed tube gauge of metal or clad with a material that is not subject to rapid deterioration
device is authorized for determining the weight of methyl mercaptan by the lading. Multi-unit tank car tanks must be nickel-clad and have
in Specification 105A300W tanks instead of weighing. reclosing pressure devices incorporating a fusible plug having a yield
(f) [Reserved] temperature of 79.44°C (175°F). Reclosing pressure devices must be
(g) Special requirements for hydrogen chloride, refrigerated liquid, vapor tight at 54.44°C (130°F).
and vinyl fluoride, stabilized. (n) Special requirements for hydrogen. Each tank car must be
(1) The shipper shall notify the Federal Railroad Administration equipped with one or more pressure relief devices. The discharge
whenever a tank car is not received by the consignee within 20 days outlet for each pressure relief device must be connected to a
from the date of shipment. Notification to the Federal Railroad Adminis- manifold having a non-obstructed discharge area of at least 1.5 times
tration may be made by e-mail to Hmassist@fra.dot.gov or telephone the total discharge area of the pressure relief devices connected to
call to (202) 493-6229. the manifold. All manifolds must be connected to a single common
(2) A tank car containing hydrogen chloride, refrigerated liquid header having a non-obstructed discharge pointing upward and
must have the auxiliary valve on the pressure relief device closed extending above the top of the car. The header and the header
during transportation. outlet must each have a non-obstructed discharge area at least
(3) See §179.102-17 of this subchapter for additional requirements. equal to the total discharge area of the manifolds connected to
(4) Tank cars containing hydrogen chloride, refrigerated liquid, the header. The header outlet must be equipped with an ignition
must be unloaded to such an extent that any residue remaining in the device that will instantly ignite any hydrogen discharged through
tank at a reference temperature of 32°C (90°F) will not actuate the the pressure relief device.
reclosing pressure relief device. (o) Special requirements for carbon dioxide, refrigerated liq-
(h) [Reserved] uid and nitrous oxide, refrigerated liquid. Each tank car must
have an insulation system so that the thermal conductance is not
(i) [Reserved]
more than 0.613 kilojoules per hour, per square meter, per degree
(j) Special requirements for materials having a primary or sec- Celsius (0.03 B.t.u. per square foot per hour, per degree Fahrenheit)
ondary Division 2.1 (flammable gas) hazard. For single unit tank temperature differential. Each tank car must be equipped with one
cars, interior pipes of loading and unloading valves, sampling devices, reclosing pressure relief valve having a start-to-discharge pressure
and gauging devices with an opening for the passage of the lading not to exceed 75 percent of the tank test pressure and one non-
exceeding 1.52 mm (0.060 inch) diameter must be equipped with reclosing pressure relief valve having a rupture disc design to burst
excess flow valves. For single unit tank cars constructed before Janu- at a pressure less than the tank test pressure. The discharge
ary 1, 1972, gauging devices must conform to this paragraph by no capacity of each pressure relief device must be sufficient to prevent
later than July 1, 2006. The protective housing cover must be provided building up of pressure in the tank in excess of 82.5 percent of
with an opening, with a weatherproof cover, above each pressure the test pressure of the tank. Tanks must be equipped with two
relief valve that is concentric with the discharge of the pressure relief regulating valves set to open at a pressure not to exceed 24.1 Bar
valve and that has an area at least equal to the valve outlet area. (350 psig) on DOT 105A500W tanks and at a pressure not to exceed
Class DOT 109 tank cars and tank cars manufactured from aluminum 27.6 Bar (400 psig) on DOT 105A600W tanks. Each regulating valve
or nickel plate are not authorized. and pressure relief device must have its final discharge piped to
(k) Special requirements for chlorine. Tank cars built after Sep- the outside of the protective housing.
tember 30, 1991, must have an insulation system consisting of 5.08 cm
(2 inches) glass fiber placed over 5.08 cm (2 inches) of ceramic fiber.
Tank cars must have excess flow valves on the interior pipes of liquid §173.315@Compressed gases in cargo tanks and portable tanks.
discharge valves. Tank cars constructed to a DOT 105A500W specifi- (a) Liquefied compressed gases that are transported in UN porta-
cation may be marked as a DOT 105A300W specification with the size ble tanks, DOT specification portable tanks, or cargo tanks must be
and type of reclosing pressure relief valves required by the marked prepared in accordance with this section, §173.32, §173.33 and sub-
375
10/2007 C-III [M-1002] 531

APPENDIX X M-1002
April 2007 §173.318—§173.319
pressure control valve, under conditions of incipient opening, with the PRESSURE CONTROL VALVE SETTING OR RELIEF VALVE SETTING
tank in a level attitude. Maximum permitted filling density (percent by weight)
(e) Temperature. A flammable cryogenic liquid in a cargo tank at Maximum set-to-discharge Carbon Methane or
the start of travel must be at a temperature sufficiently cold that the pressure (psig) monoxide Ethylene Hydrogen natural gas
pressure setting of the pressure control valve or the required pressure 175 62.5 45.8
relief valve, whichever is lower, will not be reached in less time than 285 56.0
the marked rated holding time for the cryogenic liquid (see paragraph
Design service temperature. −320°F. −155°F. −423°F. −260°F.
(g)(3) of this section and §178.338-9(b) of this subchapter).
(f) Specification MC-338 (§178.338 of this subchapter) cargo
tanks are authorized for the shipment of the following cryogenic liquids (4) Mixtures of cryogenic liquid. Where charging requirements
subject to the following additional requirements: are not specifically prescribed in this paragraph (f), the cryogenic
(1) For purposes of this section, “filling density” is defined as the liquid must be shipped in packagings and under conditions approved
percent ratio of the weight of lading in the tank to the weight of water by the Associate Administrator.
that the tank will hold at the design service temperature (one pound (g) One-way travel time; marking. The jacket of a cargo tank to
of water = 27.737 cubic inches at 60°F., or one gallon of water = 231 be used to transport a flammable cryogenic liquid must be marked
cubic inches at 60°F. and weighs 8.32828 pounds). on its right side near the front, in letters and numbers at least two
(2) Air, argon, helium, nitrogen, and oxygen, cryogenic liquids inches high, “One-Way-Travel-Time hrs.”, with the blank filled
must be loaded and shipped in accordance with the following table: in with a number indicating the one-way travel time (OWTT), in hours,
of the cargo tank for the flammable cryogenic liquid to be transported.
PRESSURE CONTROL VALVE SETTING OR RELIEF VALVE SETTING A cargo tank that is partially unloaded at one or more locations must
Maximum permitted filling density (percent by weight)
have additional marking “One-Way-Travel-Time hrs.
Maximum set-to-discharge psig to psig at percent filling density,” with the second
pressure (psig) Air Argon Helium Nitrogen Oxygen blank filled in with the pressure existing after partial unloading and
26 12.5 the third blank filled in with the set-to-discharge pressure of the control
30 80.3 129 12.5 74 105 valve or pressure relief valve, and the fourth blank with the filling
40 79.2 12.5
density following partial unloading. Multiple OWTT markings for differ-
ent pressure levels are permitted. The abbreviation “OWTT” may be
50 78.0 12.5
used in place of the words “One-way-travel-time” in the marking re-
55 77.3 125 12.5 71 102 quired by this paragraph.
60 76.9 12.5 (1) OWTT is based on the marked rated holding time (MRHT) of
80 75.3 12.5
the cargo tank for the cryogenic liquid to be transported in the cargo
tank. If the MRHT for the flammable cryogenic liquid is not displayed
85 75.1 121 12.5 99
on or adjacent to the specification plate, this MRHT may be derived.
100 73.0 12.5 (2) The MRHT is converted to OWTT, in hours, as follows:
105 73.7 12.5 67 (i) For a tank with an MRHT of 72 hours or less,
120 72.2 12.5
OWTT = (MRHT − 24)/2
(ii) For a tank with an MRHT greater than 72 hours,
140 71.4 12.5
OWTT = MRHT − 48
145 70.9 115 12.5 64 94 (3) Each cargo tank motor vehicle used to transport a flammable
180 68.3 12.5 cryogenic liquid must be examined after each shipment to determine
200 67.3 110 12.5 61 91
its actual holding time. The record required by §177.840(h) of this
subchapter may be used for this determination. If the examination
250 63.3 106 12.5 57 87
indicates that the actual holding time of the cargo tank, after adjust-
275 62.3 105 12.5 56 86 ment to reflect an average ambient temperature of 85°F, is less than
325 59.4 101 53 83 90 percent of the marked rated holding time (MRHT) for the cryogenic
Design service temperature. −320°F. −320°F. −452°F. −320°F. −320°F. liquid marked on the specification plate or adjacent thereto (see
§178.338-18(b) of this subchapter), the tank may not be refilled with
any flammable cryogenic liquid until it is restored to its marked rated
(3) Carbon monoxide, hydrogen (minimum 95 percent para-hy- holding time value or it is remarked with the actual marked rated
drogen), ethylene, and methane or natural gas, cryogenic liquids holding time determined by this examination. If the name of the flamma-
must be loaded and shipped in accordance with the following table: ble cryogenic liquid that was transported and its marked rated holding
time is not displayed on or adjacent to the specification plate, this
PRESSURE CONTROL VALVE SETTING OR RELIEF VALVE SETTING
requirement may be met by deriving the MRHT of the cargo tank for
that flammable cryogenic liquid and comparing that derived MRHT
Maximum set-to-discharge Carbon Methane or with the actual holding time after adjustment.
pressure (psig) monoxide Ethylene Hydrogen natural gas
13 6.6
§173.319@Cryogenic liquids in tank cars. (a) General require-
15 75.0 6.6 40.5 ments. (1) A tank car containing a flammable cryogenic liquid may
17 74.0 6.6 not be shipped unless it was loaded by, or with the consent of, the
20 53.5 40.0 owner of the tank car.
25 73.0 (2) The amount of flammable cryogenic liquid loaded into a tank
30 72.0 52.7 6.3 39.1 car must be determined, either by direct measurement or by calcula-
35 tion based on weight, to verify that the tank has not been filled to a level
40 52.0 38.6
in excess of the limits specified in paragraph (d)(2) of this section. The
weight of any flammable cryogenic liquid loaded, except hydrogen,
45 71.5
must be checked by use of scales after disconnecting the loading line.
50 51.4 6.0 38.2
(3) The shipper shall notify the Federal Railroad Administration
55 whenever a tank car containing any flammable cryogenic liquid is not
60 50.8 received by the consignee within 20 days from the date of shipment.
70 50.2 5.7 37.5 Notification to the Federal Railroad Administration may be made by
90 49.2 e-mail to Hmassist@fra.dot.gov or telephone call to (202) 493-6229.
95 (4) A tank car may not be loaded with any flammable cryogenic
100 48.4 5.4 36.6 liquid:
115 48.2
(i) That may combine chemically with any residue in the tank to
produce an unsafe condition,
125 5.0
(ii) That is colder than the design service temperature of the tank,
150 4.5
(iii) If the average daily pressure rise in the tank exceeded 3 psig
383
C-III [M-1002] 532 10/2007

M-1002 APPENDIX X
§173.319—§173.323 April 2007
during the prior shipment, (4) Each rupture disc must be replaced every 12 months, and the
(iv) Unless it is marked with the name of contents, in accordance replacement date must be marked on the car near the pressure relief
with §172.330 of this subchapter. valve information.
(b) When a tank car containing a flammable cryogenic liquid is (5) Pressure relief valves and alternate pressure relief valves must
offered for transportation: be tested every five years. The start-to-discharge pressure and vapor
(1) At least 0.5 percent outage must be provided below the inlet tight pressure requirements for the pressure relief valves must be as
of the pressure relief or pressure control valve at the start-to-discharge specified in §179.401-1 of this subchapter. The alternate pressure
pressure setting of the valve, with the tank car in a level attitude, and relief device values specified in §179.401-1 of this subchapter for a
(2) The absolute pressure in the annular space must be less than DOT-113C120W tank car apply to a DOT-113D120W tank car.
75 microns of mercury.
(c) Temperature. A flammable cryogenic liquid must be loaded §173.320@Cryogenic liquids; exceptions. (a) Atmospheric gases
into a tank car at such a temperature that the average daily pressure and helium, cryogenic liquids, in Dewar flasks, insulated cylinders,
rise during transportation will not exceed 3 psig (see paragraph insulated portable tanks, insulated cargo tanks, and insulated tank
(a)(4)(iii) of this section). cars, designed and constructed so that the pressure in such packag-
(d) A Class DOT-113 tank car is authorized for the shipment of the ings will not exceed 25.3 psig under ambient temperature conditions
following cryogenic liquids subject to the following additional require- during transportation are not subject to the requirements of this sub-
ments: chapter when transported by motor vehicle or railcar except as speci-
(1) For purposes of this section, “filling density” is defined as the fied in paragraphs (a)(1), (a)(2), and (a)(3) of this section.
percent ratio of the weight of lading in the tank to the weight of water (1) §§171.15 and 171.16 of this subchapter pertaining to the re-
that the tank will hold at the design service temperature (one pound porting of incidents, not including a release that is the result of venting
of water = 27.737 cubic inches at 60°F., or one gallon of water = 231 through a pressure control valve, or the neck of the Dewar flask.
cubic inches at 60°F. and weighs 8.32828 pounds). (2) Subparts A, B, C, D, G and H of part 172, (§§174.24 for rail
(2) Ethylene, and hydrogen (minimum 95 percent parahydro- and 177.817 for highway) and in addition, part 172 in its entirety for
gen), cryogenic liquids must be loaded and shipped in accordance oxygen.
with the following table: (3) Subparts A and B of part 173, and §§174.1, 177.800, 177.804,
PRESSURE CONTROL VALVE SETTING OR RELIEF VALVE SETTING and 177.823 of this subchapter.
(b) The requirements of this subchapter do not apply to atmo-
Maximum set-to-discharge spheric gases and helium:
pressure (psig) Ethylene Ethylene Ethylene Hydrogen (1) During loading and unloading operations (pressure rises may
17 6.60. exceed 25.3 psig); or
45 52.8 (2) When used in operation of a process system; such as a refrigera-
75 51.1 51.1 tion system (pressure may exceed 25.3 psig).
Maximum pressure when 10 psig 10 psig 20 psig (c) For transportation aboard aircraft, see the ICAO Technical In-
offered for transportation. structions (IBR, see §171.7 of this subchapter), Packing Instruction
Design service temperature Minus 260°F. Minus 260°F. Minus 155°F. Minus 202 and the packaging specifications in part 6, chapter 5.
423°F.
Specification (see 113D60W 113C120W 113D120W 113A175W. §173.321@Ethylamine. Ethylamine must be packaged as follows:
§180.507(b)(3) of this 113C60W 113A60W.
subchapter)
(a) In 1A1 drums which meet Packing Group I performance level
requirements.
(e) Special requirements for class DOT-113 tank cars. (1) A (b) In specification cylinders as prescribed for any compressed
class DOT-113 tank car need not be periodically pressure tested; gas except acetylene.
however, each shipment must be monitored to determine the average
daily pressure rise in the tank car. If the average daily pressure rise §173.322@Ethyl chloride. Ethyl chloride must be packaged in any
during any shipment exceeds 0.2 Bar (3 psig) per day, the tank must of the following single or combination non-bulk packagings which
be tested for thermal integrity prior to any subsequent shipment. meet Packing Group I performance level requirements:
(2) Thermal integrity test. When required by paragraph (e)(1) of (a) In 4C1, 4C2, 4D or 4F wooden boxes with glass, earthenware,
this section, either of the following thermal integrity tests may be used: or metal inner receptacles not over 500 g (17.6 ounces) capacity each;
(i) Pressure rise test. The pressure rise in the tank may not ex- (b) In 4G fiberboard boxes with glass, earthenware, or metal inner
ceed 0.34 Bar (5 psig) in 24 hours. When the pressure rise test receptacles not over 500 g (17.6 ounces) capacity each. Outer pack-
is performed, the absolute pressure in the annular space of agings may not exceed 30 kg (66 pounds) gross weight;
the loaded tank car may not exceed 75 microns of mercury at (c) In 1A1 drums of not over 100 L (26 gallons) capacity each; or
the beginning of the test and may not increase more than 25 (d) In specification cylinders as prescribed for any compressed
microns during the 24-hour period; or gas except acetylene.
(ii) Calculated heat transfer rate test. The insulation system must
be performance tested as prescribed in §179.400-4 of this §173.323@Ethylene oxide. (a) For packaging ethylene oxide in
subchapter. When the calculated heat transfer rate test is per- non-bulk packagings, silver mercury or any of its alloys or copper
formed, the absolute pressure in the annular space of the may not be used in any part of a packaging, valve, or other packaging
loaded tank car may not exceed 75 microns of mercury at the appurtenance if that part, during normal conditions of transportation,
beginning of the test and may not increase more than 25 mi- may come in contact with ethylene oxide liquid or vapor. Copper
crons during the 24-hour period. The calculated heat transfer alloys may be used only where gas mixtures do not contain free
rate in 24 hours may not exceed: acetylene at any concentration that will form copper acetylene. All
(A) 120 percent of the appropriate standard heat transfer rate packaging and gaskets must be constructed of materials which are
specified in §179.401-1 of this subchapter, for DOT- compatible with ethylene oxide and do not lower the auto-ignition
113A60W and DOT-113C120W tank cars; temperature of ethylene oxide.
(B) 122.808 joules (0.1164 Btu/day/lb.) of inner tank car water (b) Ethylene oxide must be packaged in one of the following:
capacity, for DOT-113A175W tank cars; (1) In hermetically sealed glass or metal inner packagings suitably
(C) 345.215 joules (0.3272 Btu/day/lb.) of inner tank car water cushioned in an outer package authorized by §173.201(b). The maxi-
capacity, for DOT-113C60W and 113D60W tank cars; or mum quantity permitted in any glass inner packaging is 100 g (3.5
(D) 500.09 joules (0.4740 Btu/day/lb.) of inner tank car water ounces), and the maximum quantity permitted in any metal inner pack-
capacity, for DOT-113D120W tank cars. aging is 340 g (12 ounces). After filling, each inner packaging shall
(3) A tank car that fails a test prescribed in paragraph (e)(2) of this be determined to be leak-tight by placing the inner packaging in a
section must be removed from hazardous materials service. A tank hot water bath at a temperature, and for a period of time, sufficient
car removed from hazardous materials service because it failed a test to ensure that an internal pressure equal to the vapor pressure of
prescribed in paragraph (e)(2) of this section may not be used to ethylene oxide at 55°C is achieved. The total quantity in any outer
transport a hazardous material unless the tank car conforms to all packaging shall not exceed 100 g (3.5 ounces), and the total quantity
applicable requirements of this subchapter. in any outer packaging containing only metal inner packagings shall
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APPENDIX X M-1002
April 2007 §179.1
PART 179
SPECIFICATIONS FOR TANK CARS
Subject Sec. Page Subject Sec. Page
Subpart A—Introduction, Approvals and Reports General specifications applicable to non-pres-
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179.1 589 sure tank car tanks (Class DOT–111) . . . . . . . 179.200 597
Definitions and abbreviations . . . . . . . . . . . . . . 179.2 590 Individual specification requirements applicable
Procedure for securing approval . . . . . . . . . . . . 179.3 590 to non-pressure tank car tanks . . . . . . . . . . . 179.201 600
Changes in specifications for tank cars . . . . . . . 179.4 590 General specifications applicable to nonpressure
Certificate of construction . . . . . . . . . . . . . . . . 179.5 590 tank car tanks consisting of an inner container
Repairs and alterations . . . . . . . . . . . . . . . . . . 179.6 590 supported within an outer shell (class DOT–
Quality assurance program . . . . . . . . . . . . . . . 179.7 590 115) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179.220 602
Individual specification requirements applicable
Subpart B—General Design Requirements to tank car tanks consisting of an inner con-
Tank mounting . . . . . . . . . . . . . . . . . . . . . . . . 179.10 591 tainer supported within an outer shell . . . . . . . 179.221 604
Welding certification . . . . . . . . . . . . . . . . . . . . 179.11 591 Subpart E—Specifications for Multi-Unit Tank Car Tanks
Interior heater systems . . . . . . . . . . . . . . . . . . 179.12 591 (Classes DOT–106A and 110AW)
Tank car capacity and gross weight limitation . . 179.13 591 General specifications applicable to multi-unit
Coupler vertical restraint system . . . . . . . . . . . . 179.14 591 tank car tanks designed to be removed from
Pressure relief devices . . . . . . . . . . . . . . . . . . 179.15 591 car structure for filling and emptying (Classes
Tank-head puncture-resistance systems . . . . . . 179.16 592 DOT–106A and 110AW) . . . . . . . . . . . . . . . . 179.300 605
Thermal protection systems . . . . . . . . . . . . . . . 179.18 592 Individual specification requirements for multi-unit
Service equipment; protection systems . . . . . . . 179.20 592 tank car tanks . . . . . . . . . . . . . . . . . . . . . . . 179.301 606
Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179.22 592
Subpart F—Specifications for Cryogenic Liquid Tank Car Tanks
Subpart C—Specifications for Pressure Tank Car Tanks and Seamless Steel Tanks
(Classes DOT–105, 109, 112 and 114) (Classes DOT–113 and 107A)
General specification applicable to cryogenic
General specifications applicable to pressure
liquid tank car tanks . . . . . . . . . . . . . . . . . . 179.400 607
tank car tanks . . . . . . . . . . . . . . . . . . . . . . . 179.100 592
to inner tanks for cryogenic liquid tank car
to pressure tank car tanks . . . . . . . . . . . . . . 179.101 594
tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179.401 611
Special commodity requirements for pressure
Specification DOT–107A**** seamless steel tank
tank car tanks . . . . . . . . . . . . . . . . . . . . . . . 179.102 595
car tanks . . . . . . . . . . . . . . . . . . . . . . . . . . 179.500 611
Special requirements for class 114A * * * tank
Appendix A to part 179—Procedures for Tank-
car tanks . . . . . . . . . . . . . . . . . . . . . . . . . . 179.103 596
Head Puncture-Resistance Test . . . . . . . . . . . 614
Subpart D—Specifications for Non-Pressure Tank Car Tanks Appendix B to part 179—Procedures for
(Classes DOT–111AAW and 115AW) Simulated Pool and Torch-Fire Testing . . . . . . 614
PUBLISHER’S NOTE
This Part outlines the requirements for constructing tank cars. It is divided into basically five sections. The first
section deals with general requirements for all tank cars. The second section covers pressure tank cars used
primarily for compressed gases and certain high risk liquids. The third section covers non-pressure tank cars used
to transport liquids. The fourth section covers multi-unit tank car tanks. These tank cars are much smaller than
the normal tank car and do not have an under carriage or trucks to support the tank and must be transported on
flat cars. The fifth section covers cryogenic liquid tank cars and seamless steel tanks.
The general requirements in the first section are covered in Subpart A and Subpart B. The remaining four
sections are assigned their own Subpart.
Subpart A
INTRODUCTION, APPROVALS AND REPORTS
§179.1@General. (a) This part prescribes the specifications for (d) Any person who performs a function prescribed in this part,
tanks that are to be mounted on or form part of a tank car and which shall perform that function in accordance with this part.
are to be marked with a DOT specification. (e) When this part requires a tank to be marked with a DOT specifi-
(b) Except as provided in paragraph (c) of this section, tanks to cation (for example, DOT-105A100W), compliance with that require-
which this part is applicable, must be built to the specifications pre- ment is the responsibility of the tank builder. Marking the tank with
scribed in this part. the DOT specification shall be understood to certify compliance by
(c) Tanks built to specifications predating those in this part may the builder that the functions performed by the builder, as prescribed
continue in use as provided in §180.507 of this subchapter. in this part, have been performed in compliance with this part.
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M-1002 APPENDIX X
§179.1—§179.7 April 2007
(f) The tank builder should inform each person to whom that tank all the requirements of the specifications.
is transferred of any specification requirements which have not been (d) When cars or tanks which are covered on one application and
met at time of transfer. are identical in all details are built in series, one certificate shall suffice
for each series when submitted to the Executive Director—Tank Car
§179.2@Definitions and abbreviations. (a) The following apply in Safety, AAR. One copy of the Certificate of Construction must be
part 179: furnished to the Executive Director—Tank Car Safety, AAR for each
(1) AAR means Association of American Railroads. car number of consecutively numbered group or groups covered by
(2) Approved means approval by the AAR Tank Car Committee. the original application.
(3) ASTM means American Society for Testing and Materials.
(4) [Reserved]
(5) Definitions in part 173 of this chapter also apply. §179.6@Repairs and alterations. For procedure to be followed in
(6) F means degrees Fahrenheit. making repairs or alterations, see appendix R of the AAR Specifica-
(7) NGT means National Gas Taper Threads. tions for Tank Cars (IBR, see §171.7 of this subchapter).
(8) NPT means an American Standard Taper Pipe Thread conform-
ing to the requirements of NBS Handbook H–28 (IBR, see §171.7 of
this subchapter).
(9) [Reserved] §179.7@Quality assurance program. (a) At a minimum, each tank
(10) Tank car facility means an entity that manufactures, repairs, car facility shall have a quality assurance program, approved by
inspects, tests, qualifies, or maintains a tank car to ensure that the AAR, that—
tank car conforms to this part and subpart F of part 180 of this subchap- (1) Ensures the finished product conforms to the requirements of
ter, that alters the certificate of construction of the tank car, that ensures the applicable specification and regulations of this subchapter;
the continuing qualification of a tank car by performing a function (2) Has the means to detect any nonconformity in the manufactur-
prescribed in parts 179 or 180 of this subchapter, or that makes ing, repair, inspection, testing, and qualification or maintenance pro-
any representation indicating compliance with one or more of the gram of the tank car; and
requirements of parts 179 or 180 of this subchapter. (3) Prevents non-conformities from recurring.
(11) Tanks means tank car tanks.
(b) At a minimum, the quality assurance program must have the
(b) [Reserved]
following elements—
§179.3@Procedure for securing approval. (a) Application for ap- (1) Statement of authority and responsibility for those persons in
proval of designs, materials and construction, conversion or alteration charge of the quality assurance program.
of tank car tanks under these specifications, complete with detailed (2) An organizational chart showing the interrelationship between
prints, must be submitted in prescribed form to the Executive Direc- managers, engineers, purchasing, construction, inspection, testing,
tor—Tank Car Safety, AAR, for consideration by its Tank Car Commit- and quality control personnel.
tee and other appropriate committees. Approval or rejections of appli- (3) Procedures to ensure that the latest applicable drawings, de-
cations based on appropriate committee action will be issued by the sign calculations, specifications, and instructions are used in manufac-
executive director. ture, inspection, testing, and repair.
(b) When, in the opinion of the Committee, such tanks or equipment (4) Procedures to ensure that the fabrication and construction mate-
are in compliance with the requirements of this subchapter, the appli- rials received are properly identified and documented.
cation will be approved.
(5) A description of the manufacturing, repair, inspection, testing,
(c) When such tanks or equipment are not in compliance with the
and qualification or maintenance program, including the acceptance
requirements of this subchapter, the Committee may recommend ser-
criteria, so that an inspector can identify the characteristics of the
vice trials to determine the merits of a change in specifications. Such
tank car and the elements to inspect, examine, and test at each point.
service trials may be conducted only if the builder or shipper applies
for and obtains a special permit. (6) Monitoring and control of processes and product characteristics
during production.
§179.4@Changes in specifications for tank cars. (a) Proposed (7) Procedures for correction of nonconformities.
changes in or additions to specifications for tanks must be submitted (8) Provisions indicating that the requirements of the AAR Specifica-
to the Executive Director—Tank Car Safety, AAR, for consideration tions for Tank Cars (IBR, see §171.7 of this subchapter), apply.
by its Tank Car Committee. An application for construction of tanks to (9) Qualification requirements of personnel performing non-de-
any new specification may be submitted with proposed specification. structive inspections and tests.
Construction should not be started until the specification has been
approved or a special permit has been issued. When proposing a (10) Procedures for evaluating the inspection and test technique
new specification, the applicant shall furnish information to justify a employed, including the accessibility of the area and the sensitivity
new specification. This data should include the properties of the lading and reliability of the inspection and test technique and minimum de-
and the method of loading and unloading. tectable crack length.
(b) The Tank Car Committee will review the proposed specifications (11) Procedures for the periodic calibration and measurement of
at its earliest convenience and report its recommendations through inspection and test equipment.
the Executive Director—Tank Car Safety to the Department. The rec- (12) A system for the maintenance of records, inspections, tests,
ommendation will be considered by the Department in determining and the interpretation of inspection and test results.
appropriate action. (c) Each tank car facility shall ensure that only personnel qualified
for each non-destructive inspection and test perform that particular
§179.5@Certificate of construction. (a) Before a tank car is operation.
placed in service, the party assembling the completed car shall furnish
(d) Each tank car facility shall provide written procedures to its
a Certificate of Construction, Form AAR 4–2 to the owner and the
employees to ensure that the work on the tank car conforms to the
Executive Director—Tank Car Safety, AAR, certifying that the tank,
specification, AAR approval, and owner’s acceptance criteria.
equipment, and car fully conforms to all requirements of the specifi-
cation. (e) Each tank car facility shall train its employees in accordance
(b) When cars or tanks are covered in one application and are with subpart H of part 172 of this subchapter on the program and
identical in all details are built in series, one certificate will suffice procedures specified in paragraph (b) of this section to ensure quality.
for each series when submitted to the Executive Director—Tank Car (f) No tank car facility may manufacture, repair, inspect, test, qualify
Safety, AAR. or maintain tank cars subject to requirements of this subchapter,
(c) If the owner elects to furnish service equipment, the owner shall unless it is operating in conformance with a quality assurance program
furnish the Executive Director—Tank Car Safety, AAR, a report in and written procedures required by paragraphs (a) and (b) of this
prescribed form, certifying that the service equipment complies with section.
590
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APPENDIX X M-1002
April 2007 §179.10—§179.15
Subpart B
GENERAL DESIGN REQUIREMENTS
§179.10@Tank mounting. (a) The manner in which tanks are (a) Performance standard. Each tank must have a pressure relief
attached to the car structure shall be approved. The use of rivets to device, made of materials compatible with the lading, having sufficient
secure anchors to tanks prohibited. flow capacity to prevent pressure build-up in the tank to no more than
(b) [Reserved] the flow rating pressure of the pressure relief device in fire conditions
as defined in appendix A of the AAR Specifications for Tank Cars
§179.11@Welding certification. (a) Welding procedures, welders (IBR, see §171.7 of this subchapter).
and fabricators shall be approved. (b) Settings for reclosing pressure relief devices. (1) Except as
(b) [Reserved] provided in paragraph (b)(2) of this section, a reclosing pressure relief
valve must have a minimum start-to-discharge pressure equal to the
§179.12@Interior heater systems. (a) Interior heater systems shall sum of the static head and gas padding pressure and the lading
be of approved design and materials. If a tank is divided into compart- vapor pressure at the following reference temperatures:
ments, a separate system shall be provided for each compartment. (i) 46°C (115°F) for noninsulated tanks;
(b) Each interior heater system shall be hydrostatically tested at (ii) 43°C (110°F) for tanks having a thermal protection system incor-
not less than 13.79 bar (200 psig) and shall hold the pressure for 10 porating a metal jacket that provides an overall thermal conduc-
minutes without leakage or evidence of distress. tance at 15.5°C (60°F) of no more than 10.22 kilojoules per
hour per square meter per degree Celsius (0.5 Btu per hour/
§179.13@Tank car capacity and gross weight limitation. Tank per square foot/per degree F) temperature differential; and
cars built after November 30, 1970, must not exceed 34,500 gallons (iii) 41°C (105°F) for insulated tanks.
capacity or 263,000 pounds gross weight on rail. Existing tank cars (2)(i) The start-to-discharge pressure of a pressure relief device
may not be converted to exceed 34,500 gallons capacity or 263,000 may not be lower than 5.17 Bar (75 psig) or exceed 33 percent of
pounds gross weight on rail.
the minimum tank burst pressure.
§179.14@Coupler vertical restraint system. (a) Performance (ii) Tanks built prior to October 1, 1997 having a minimum tank
standard. Each tank car shall be equipped with couplers capable of burst pressure of 34.47 Bar (500 psig) or less may be equipped
sustaining, without disengagement or material failure, vertical loads with a reclosing pressure relief valve having a start-to-discharge
of at least 200,000 pounds (90,718.5 kg) applied in upward and down- pressure of not less than 14.5 percent of the minimum tank
ward directions in combination with buff loads of 2,000 pounds (907.2 burst pressure but no more than 33 percent of the minimum
kg), when coupled to cars which may or may not be equipped with tank burst pressure.
couplers having this vertical restraint capability. (3) The vapor tight pressure of a reclosing pressure relief valve
(b) Test verification. Except as provided in paragraph (d) of this must be at least 80 percent of the start-to-discharge pressure.
section, compliance with the requirements of paragraph (a) of this (4) The flow rating pressure must be 110 percent of the start-to-
section shall be achieved by verification testing of the coupler veritcal discharge pressure for tanks having a minimum tank burst pressure
restraint system in accordance with paragraph (c) of this section. greater than 34.47 Bar (500 psig) and from 110 percent to 130 percent
(c) Coupler vertical restraint tests. A coupler vertical restraint for tanks having a minimum tank burst pressure less than or equal to
system shall be tested under the following conditions: 34.47 Bar (500 psig).
(1) The test coupler shall be tested with a mating coupler (or simu- (5) The tolerance for a reclosing pressure relief valve is ⫾3 psi for
lated coupler) having only frictional vertical force resistance at the valves with a start-to-discharge pressure of 6.89 Bar (100 psig) or
mating interface; or a mating coupler (or simulated coupler) having less and ⫾3 percent for valves with a start-to-discharge pressure
the capabilities described in paragraph (a) of this section; greater than 6.89 Bar (100 psig).
(2) The testing apparatus shall simulate the vertical coupler per- (c) Flow capacity of pressure relief devices. The total flow capac-
formance at the mating interface and may not interfere with coupler ity of each reclosing and nonreclosing pressure relief device must
failure or otherwise inhibit failure due to force applications and reac- conform to appendix A of the AAR Specifications for Tank Cars.
tions; and (d) Flow capacity tests. The manufacturer of any reclosing or
(3) The test shall be conducted as follows: nonreclosing pressure relief device must design and test the device in
(i) A minimum of 200,000 pounds (90,718.5 kg) vertical downward accordance with appendix A of the AAR Specifications for Tank Cars.
load shall be applied continuously for at least 5 minutes to (e) Combination pressure relief systems. A non-reclosing pres-
the test coupler head simultaneously with the application of a sure relief device may be used in series with a reclosing pressure
nominal 2,000 pounds (907.2 kg) buff load; relief valve. The pressure relief valve must be located outboard of the
(ii) The procedures prescribed in paragraph (c)(3)(i) of this section, non-reclosing pressure relief device.
shall be repeated with a minimum vertical upward load of (1) When a breaking pin device is used in combination with a reclos-
200,000 pounds (90,718.5 kg); and ing pressure relief valve, the breaking pin must be designed to fail at
(iii) A minimum of three consecutive successful tests shall be per- the start-to-discharge pressure specified in paragraph (b) of this sec-
formed for each load combination prescribed in paragraphs tion, and the reclosing pressure relief valve must be designed to dis-
(c)(3)(i) and (ii) of this section. A test is successful when a charge at not greater than 95 percent of the start-to-discharge pressure.
vertical disengagement or material failure does not occur dur- (2) When a rupture disc is used in combination with a reclosing
ing the application of any of the loads prescribed in this para- pressure relief valve, the rupture disc must be designed to burst at the
graph. pressure specified in paragraph (b) of this section, and the reclosing
(d) Authorized couplers. As an alternative to the test verifications pressure relief valve must be designed to discharge at not greater
in paragraph (c) of this section, the following couplers are authorized: than 95 percent of the pressure. A device must be installed to detect
(1) E double shelf couplers designated by the Association of Ameri- any accumulation of pressure between the rupture disc and the reclos-
can Railroads’ Catalog Nos., SE60CHT, SE60CC, SE60CHTE, ing pressure relief valve. The detection device must be a needle valve,
SE60CE, SE60DC, SE60DE, SE67CC, SE67CE, SE67BHT, SE67BC, trycock, or tell-tale indicator. The detection device must be closed
SE67BHTE, SE67BE, SE68BHT, SE68BC, SE68BHTE, SE68BE, during transportation.
SE69AHTE, and SE69AE. (3) The vapor tight pressure and the start-to-discharge tolerance
(2) F double shelf couplers designated by the Association of Ameri- is based on the discharge setting of the reclosing pressure relief
can Railroads’ Catalog Nos., SF70CHT, SF70CC, SF70CHTE, SF70CE, device.
SF73AC, SF73AE, SF73AHT, SF73AHTE, SF79CHT, SF79CC, (f) Non-reclosing pressure relief device. In addition to para-
SF79CHTE, and SF79CE. graphs (a), (b)(4), (c), and (d) of this section, a non-reclosing pressure
relief device must conform to the following requirements:
§179.15@Pressure relief devices. Except for DOT Class 106, 107, (1) A non-reclosing pressure relief device must incorporate a rupture
110, and 113 tank cars, tanks must have a pressure relief device, disc designed to burst at a pressure equal to the greater of 100% of the
made of material compatible with the lading, that conforms to the tank test pressure, or 33% of the tank burst pressure.
following requirements: (2) The approach channel and the discharge channel may not
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M-1002 APPENDIX X
§179.15—§179.100–4 April 2007
reduce the required minimum flow capacity of the pressure relief so that there will be no release of any lading within the tank car, except
device. release through the pressure relief device, when subjected to:
(3) The non-reclosing pressure relief device must be designed to (1) A pool fire for 100 minutes; and
prevent interchange with other fittings installed on the tank car, must (2) A torch fire for 30 minutes.
have a structure that encloses and clamps the rupture disc in position (b) Thermal analysis. (1) Compliance with the requirements of
(preventing any distortion or damage to the rupture disc when properly paragraph (a) of this section shall be verified by analyzing the fire
applied), and must have a cover, with suitable means of preventing effects on the entire surface of the tank car. The analysis must consider
misplacement, designed to direct any discharge of the lading the fire effects on and heat flux through tank discontinuities, protective
downward. housings, underframes, metal jackets, insulation, and thermal protec-
(4) The non-reclosing pressure relief device must be closed with tion. A complete record of each analysis shall be made, retained,
a rupture disc that is compatible with the lading and manufactured and upon request, made available for inspection and copying by an
in accordance with Appendix A of the AAR Specifications for Tank authorized representative of the Department. The procedures outlined
Cars. The tolerance for a rupture disc is +0 to −15 percent of the in “Temperatures, Pressures, and Liquid Levels of Tank Cars Engulfed
burst pressure marked on the disc. in Fires,” DOT/FRA/OR&D-84/08.11, (1984), Federal Railroad Adminis-
(g) Location of relief devices. Each pressure relief device must tration, Washington, DC (available from the National Technical Infor-
communicate with the vapor space above the lading as near as practi- mation Service, Springfield, VA) shall be deemed acceptable for ana-
cable on the longitudinal center line and center of the tank. lyzing the fire effects on the entire surface of the tank car.
(h) Marking of pressure relief devices. Each pressure relief de- (2) When the analysis shows the thermal resistance of the tank car
vice and rupture disc must be permanently marked in accordance does not conform to paragraph (a) of this section, the thermal resis-
with the appendix A of the AAR Specifications for Tank Cars. tance of the tank car must be increased by using a system listed by
the Department under paragraph (c) of this section or by testing a
§179.16@Tank-head puncture-resistance systems. (a) Perfor- new or untried system and verifying it according to appendix B of
mance standard. When the regulations in this subchapter require a this part.
tank-head puncture-resistance system, the system shall be capable (c) Systems that no longer require test verification. The Depart-
of sustaining, without any loss of lading, coupler-to-tank-head impacts ment maintains a list of thermal protection systems that comply with
at relative car speeds of 29 km/hour (18 mph) when: the requirements of appendix B of this part and that no longer require
(1) The weight of the impact car is at least 119,295 kg (263,000 test verification. Information necessary to equip tank cars with one of
pounds); these systems is available in the PHMSA Records Center, Pipeline
(2) The impacted tank car is coupled to one or more backup cars and Hazardous Materials Safety Administration, 400 Seventh Street,
that have a total weight of at least 217,724 kg (480,000 pounds) and SW., Washington, DC 20590–0001.
the hand brake is applied on the last “backup” car; and
(3) The impacted tank car is pressurized to at least 6.9 Bar (100 psig).
§179.20@Service equipment; protection systems. If an applica-
(b) Verification by testing. Compliance with the requirements of
ble tank car specification authorizes location of filling or discharge
paragraph (a) of this section shall be verified by full-scale testing
connections in the bottom shell, the connections must be designed,
according to Appendix A of this part.
constructed, and protected according to paragraphs E9.00 and
(c) Alternative compliance by other than testing. As an alterna-
E10.00 of the AAR Specifications for Tank Cars (IBR, see §171.7 of
tive to requirements prescribed in paragraph (b) of this section, com-
this subchapter).
pliance with the requirements of paragraph (a) of this section may be
met by installing full-head protection (shields) or full tank-head jackets
on each end of the tank car conforming to the following: §179.22@Marking. In addition to any other marking requirement in
(1) The full-head protection (shields) or full tank-head jackets must this subchapter, the following marking requirements apply:
be at least 1.27 cm (0.5 inch) thick, shaped to the contour of the tank (a) Each tank car must be marked according to the requirements
head and made from steel having a tensile strength greater than in appendix C of the AAR Specifications for Tank Cars (IBR, see
379.21 N/mm2 (55,000 psi). §171.7 of this subchapter).
(2) The design and test requirements of the full-head protection (b) Each tank car that requires a tank-head puncture-resistance
(shields) or full tank-head jackets must meet the impact test require- system must have the letter “S” substituted for the letter “A” in the
ments in Section 5.3 of the AAR Specifications for Tank Cars (IBR, specification marking.
see §171.7 of this subchapter). (c) Each tank car that requires a tank-head puncture-resistance
(3) The workmanship must meet the requirements in Section C, system, a thermal protection system, and a metal jacket must have
Part II, Chapter 5, of the AAR Specifications for Design, Fabrication, the letter “J” substituted for the letter “A” or “S” in the specification
and Construction of Freight Cars (IBR, see §171.7 of this subchapter). marking.
(d) Each tank car that requires a tank-head puncture-resistance
§179.18@Thermal protection systems. (a) Performance stan- system, a thermal protection system, and no metal jacket must have
dard. When the regulations in this subchapter require thermal protec- the letter “T” substituted for the letter “A” or “S” in the specification
tion on a tank car, the tank car must have sufficient thermal resistance marking.
Subpart C
SPECIFICATIONS FOR PRESSURE TANK CAR TANKS (CLASSES DOT-105, 109, 112, 114, AND 120)
§179.100@General specifications applicable to pressure tank car provided in part 173 of this chapter, §§179.100–14, 179.101–1,
tanks. 179.102 or 179.103.
§179.100–1@Tanks built under these specifications shall comply §179.100–4@Insulation. (a) If insulation is applied, the tank shell
with the requirements of §§179.100, 179.101, and when applicable, and manway nozzle must be insulated with an approved material. The
§§179.102 and 179.103. entire insulation must be covered with a metal jacket of a thickness
not less than 11 gage (0.1196 inch) nominal (Manufacturers’ Standard
§179.100–3@Type. (a) Tanks built under this specification shall be Gauge) and flashed around all openings so as to be weather-tight.
fusion-welded with heads designed convex outward. Except as pro- The exterior surface of a carbon steel tank, and the inside surface of
vided in §179.103, they shall be circular in cross section, shall be a carbon steel jacket must be given a protective coating.
provided with a manway nozzle on top of the tank of sufficient size (b) If insulation is a specification requirement, it shall be of sufficient
to permit access to the interior, a manway cover to provide for the thickness so that the thermal conductance at 60°F is not more than
mounting of all valves, measuring and sampling devices, and a protec- 0.075 Btu per hour, per square foot, per degree F temperature differen-
tive housing. Other openings in the tank are prohibited, except as tial. If exterior heaters are attached to tank, the thickness of the insula-
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10/2007 C-III [M-1002] 537

APPENDIX X M-1002
April 2007 §179.100–4—§179.100–13
tion over each heater element may be reduced to one-half that required (2) (i) High alloy steels used to fabricate tank must be tested in
for the shell. accordance with the following procedures in ASTM A 262,
“Standard Practices for Detecting Susceptibility to Intergran-
§179.100–6@Thickness of plates. (a) The wall thickness after
ular Attack in Austenitic Stainless Steel” (IBR, see §171.7 of
forming of the tank shell and heads must not be less than that specified
this subchapter), and must exhibit corrosion rates not ex-
in §179.101, nor that calculated by the following formula:
ceeding the following:
Pd
t=
2SE Test procedures Material Corrosion rate i.p.m.
where: Practice B Types 304L and 316L 0.0040
d = Inside diameter in inches; Practice C Type 304L 0.0020
E = 1.0 welded joint efficiency; except for heads with seams = 0.9;
P = Minimum required bursting pressure in p.s.i.; (ii) Type 304L and 316L test specimens must be given a sensitizing
S = Minimum tensile strength of plate material in p.s.i., as pre- treatment prior to testing.
scribed in §179.100–7; (d) All attachments welded to tank shell must be of approved mate-
t = Minimum thickness of plate in inches after forming. rial which is suitable for welding to the tank.
(b) If plates are clad with material having tensile strength properties
at least equal to the base plate, the cladding may be considered a §179.100–8@Tank heads. (a) The tank head shape shall be an
part of the base plate when determining thickness. If cladding material ellipsoid of revolution in which the major axis shall equal the diameter
does not have tensile strength at least equal to the base plate, the of the shell adjacent to the head and the minor axis shall be one-half
base plate alone shall meet the thickness requirement. the major axis.
(c) When aluminum plate is used, the minimum width of bottom (b) Each tank head made from steel which is required to be “fine
sheet of tank shall be 60 inches, measured on the arc, but in all cases grain” by the material specification, which is hot formed at a tempera-
the width shall be sufficient to bring the entire width of the longitudinal ture exceeding 1700°F., must be normalized after forming by heating
welded joint, including welds, above the bolster. to a temperature between 1550° and 1700°F., by holding at that tem-
perature for at least 1 hour per inch of thickness (30-minute minimum),
§179.100–7@Materials. (a) Steel plate: Steel plate materials used and then by cooling in air. If the material specification requires quench-
to fabricate tank shell and manway nozzle must comply with one of ing and tempering, the treatment specified in that specification must
the following specifications with the indicated minimum tensile be used instead of the one specified above.
strength and elongation in the welded condition. The maximum allow-
able carbon content must be 0.31 percent when the individual specifi- §179.100–9@Welding. (a) All joints shall be fusion-welded in com-
cation allows carbon greater than this amount. The plates may be pliance with the requirements of AAR Specifications for Tank Cars,
clad with other approved materials. appendix W (IBR, see §171.7 of this subchapter). Welding procedures,
welders and fabricators shall be approved.
Minimum elongation in 2 (b) [Reserved]
Minimum tensile strength inches (percent) welded
Specifications (p.s.i.) welded condition1 condition (longitudinal)
§179.100–10@Postweld heat treatment. (a) After welding is com-
AAR TC128, Gr. B 81,000 19
plete, steel tanks and all attachments welded thereto must be postweld
ASTM A 3022, Gr. B 80,000 20
heat treated as a unit in compliance with the requirements of AAR
ASTM A 5162 70,000 20 Specifications for Tank Cars, appendix W (IBR, see §171.7 of this
ASTM A 5372, Class 1 70,000 23 subchapter).
1
Maximum stresses to be used in calculations. (b) For aluminum tanks, postweld heat treatment is prohibited.
2
These specifications are incorporated by reference (IBR, see §171.7 of this subchapter). (c) Tank and welded attachments, fabricated from ASTM A 240/A
(b) Aluminum alloy plate: Aluminum alloy plate material used to 240M (IBR, see §171.7 of this subchapter), Type 304L or Type 316L
fabricate tank shell and manway nozzle must be suitable for fusion weld- materials do not require postweld heat treatment, but these materials
ing and must comply with one of the following specifications (IBR, see do require a corrosion resistance test as specified in §179.100–7(c)(2).
§171.7 of this subchapter) with its indicated minimum tensile strength
and elongation in the welded condition. §179.100–12@Manway nozzle, cover and protective housing.
(a) Manway nozzles must be of approved design of forged or rolled
Minimum tensile Minimum elongation in 2 steel for steel tanks or of fabricated aluminum alloy for aluminum tanks,
strength (p.s.i.) 0 inches (percent) 0 temper,
temper, welded welded condition with an access opening of at least 18 inches inside diameter, or at
Specifications condition3 4 (longitudinal) least 14 inches by 18 inches around or oval. Each nozzle must be
ASTM B 209, Alloy 50521 25,000 18 welded to the tank and the opening reinforced in an approved manner
ASTM B 209, Alloy 50832 38,000 16
in compliance with the requirements of AAR Specifications for Tank
1
Cars, appendix E, Figure E10 (IBR, see §171.7 of this subchapter).
ASTM B 209, Alloy 5086 35,000 14
(b) Manway cover shall be machined to approved dimensions and
1
ASTM B 209, Alloy 5154 30,000 18 be of forged or rolled carbon or alloy steel, rolled aluminum alloy or
1
ASTM B 209, Alloy 5254 30,000 18 nickel when required by the lading. Minimum thickness is listed in
ASTM B 209, Alloy 5454 1
31,000 18 §179.101. Manway cover shall be attached to manway nozzle by
ASTM B 209, Alloy 5652 1
25,000 18 through or stud bolts not entering tank, except as provided in
1
For fabrication, the parent plate material may be 0, H112, or H32 temper, but design
§179.103–2(a).
calculations must be based on minimum tensile strength shown. (c) Except as provided in §179.103, protective housing of cast,
2
0 temper only. forged or fabricated approved materials must be bolted to manway
3
4
Weld filler metal 5556 must not be used. cover with not less than twenty 3⁄4-inch studs. The shearing value of
Maximum stress to be used in calculations.
the bolts attaching protective housing to manway cover must not
(c) High-alloy steel plate. exceed 70 percent of the shearing value of bolts attaching manway
(1) High-alloy steel plate must conform to the following specifica- cover to manway nozzle. Housing must have steel sidewalls not less
tions: than three-fourths inch in thickness and must be equipped with a
Minimum tensile Minimum elongation in 2 metal cover not less than one-fourth inch in thickness that can be
strength (p.s.i.) inches (percent) weld metal securely closed. Housing cover must have suitable stop to prevent
Specifications welded condition1 (longitudinal)
cover striking loading and unloading connections and be hinged on
ASTM A 240/A 240M (incorpo- 70,000 30 one side only with approved riveted pin or rod with nuts and cotters.
rated by reference; see §171.7 of
this subchapter), Type 304L Openings in wall of housing must be equipped with screw plugs or
ASTM A 240/A 240M (incorpo- 70,000 30
other closures.
rated by reference; see §171.7 of
this subchapter), Type 316L §179.100–13@Venting, loading and unloading valves, measuring
1
Maximum stresses to be used in calculations. and sampling devices. (a) Venting, loading and unloading valves
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C-III [M-1002] 538 10/2007

M-1002 APPENDIX X
§179.100–13—§179.101–1 April 2007
shall be of approved design, made of metal not subject to rapid below the tank shell. On cars with continuous center sills, the breakage
deterioration by the lading, and must withstand the tank test pressure groove or its equivalent must be above the bottom of the center sill
without leakage. The valves shall be bolted to seatings on the manway construction.
cover, except as provided in §179.103. Valve outlets shall be closed (4) The closure plug and seat shall be readily accessible or remov-
with approved screw plugs or other closures fastened to prevent able for repairs.
misplacement. (5) The closure of the washout nozzle must be equipped with a
3
(b) The interior pipes of the loading and unloading valves shall ⁄4-inch solid screw plug. Plug must be attached by at least a 1⁄4-
be anchored and, except as prescribed in §§173.314(j), 179.102 or inch chain.
179.103, may be equipped with excess flow valves of approved (6) Joints between closures and their seats may be gasketed with
design. suitable material.
(c) Gaging device, sampling valve and thermometer well are not (b) [Reserved]
specification requirements. When used, they shall be of approved
design, made of metal not subject to rapid deterioration by the lading, §179.100–16@Attachments. (a) Reinforcing pads must be used
and shall withstand the tank test pressure without leakage. Interior between external brackets and shells if the attachment welds exceed
pipes of the gauging device and sampling valve, except as prescribed 6 linear inches of 1⁄4-inch fillet or equivalent weld per bracket or bracket
in §§173.314(j), 179.102 or 179.103, may be equipped with excess leg. When reinforcing pads are used, they must not be less than
flow valves of approved design. Interior pipe of the thermometer well one-fourth inch in thickness, have each corner rounded to a 1-inch
shall be anchored in an approved manner to prevent breakage due minimum radius, and be attached to the tank by continuous fillet
to vibration. The thermometer well shall be closed by an approved welds except for venting provisions. The ultimate shear strength of
valve attached close to the manway cover, or other approved location, the bracket-to-reinforcing pad weld must not exceed 85 percent of
and closed by a screw plug. Other approved arrangements that permit the ultimate shear strength of the reinforcing pad-to-tank weld.
testing thermometer well for leaks without complete removal of the (b) Attachments not otherwise specified shall be applied by ap-
closure may be used. proved means.
(d) An excess flow valve as referred to in this specification, is a §179.100–17@Closures for openings. (a) Closures shall be of ap-
device which closes automatically against the outward flow of the proved design and made of metal not subject to rapid deterioration
contents of the tank in case the external closure valve is broken off by the lading. Plugs, if used, shall be solid, with NPT threads, and
or removed during transit. Excess flow valves may be designed with shall be of a length which will screw at least six threads inside the
a by-pass to allow the equalization of pressures. face of fitting or tank.
(e) Bottom of tank shell may be equipped with a sump or siphon (b) [Reserved]
bowl, or both, welded or pressed into the shell. Such sumps or siphon
bowls, if applied, are not limited in size and must be made of cast, §179.100–18@Tests of tanks. (a) Each tank shall be tested by
forged or fabricated metal. Each sump or siphon bowl must be of completely filling tank and manway nozzle with water or other liquid
good welding quality in conjunction with the metal of the tank shell. having similar viscosity, at a temperature which shall not exceed 100°F
When the sump or siphon bowl is pressed in the bottom of the tank during the test; and applying the pressure prescribed in §179.101.
shell, the wall thickness of the pressed section must not be less than The tank shall hold the prescribed pressure for at least 10 minutes
that specified for the shell. The section of a circular cross section tank without leakage or evidence of distress.
to which a sump or siphon bowl is attached need not comply with the (b) Insulated tanks shall be tested before insulation is applied.
out-of-roundness requirement specified in AAR Specifications for Tank (c) Caulking of welded joints to stop leaks developed during the
Cars, appendix W, W14.06 (IBR, see §171.7 of this subchapter). Any foregoing test is prohibited. Repairs in welded joints shall be made
portion of a sump or siphon bowl not forming a part of cylinder of as prescribed in AAR Specifications for Tank Cars, appendix W (IBR,
revolution must have walls of such thickness and be so reinforced see §171.7 of this subchapter).
that the stresses in the walls caused by a given internal pressure are (d) Testing of exterior heaters is not a specification requirement.
no greater than the circumferential stress that would exist under the
same internal pressure in the wall of a tank of circular cross section §179.100–19@Tests of safety relief valves. (a) Each valve shall
designed in accordance with §179.100–6(a), but in no case shall the be tested by air or gas for compliance with §179.15 before being put
wall thickness be less than that specified in §179.101–1. into service.
(b) [Reserved]
§179.100–14@Bottom outlets. (a) Bottom outlets for discharge of
§179.100–20@Stamping. (a) To certify that the tank complies with
lading is prohibited, except as provided in §179.103–3. If indicated
all specification requirements, each tank shall be plainly and perma-
in §179.101, tank may be equipped with a bottom washout of approved
nently stamped in letters and figures at least 3⁄8 inch high into the
construction. If applied, bottom washout shall be in accordance with
metal near the center of both outside heads as follows:
the following requirements:
(1) The extreme projection of the bottom washout equipment may Example of required stamping
not be more than that allowed by appendix E of the AAR Specifications
Specification DOT–105A100–W
for Tank Cars (IBR, see §171.7 of this subchapter).
(2) Bottom washout shall be of cast, forged or fabricated metal and Material ASTM A 516
shall be fusion-welded to the tank. It shall be of good weldable quality Cladding material (if any) ASTM A240–304 Clad
in conjunction with metal of tank. Tank builders initials ABC
(3) If the bottom washout nozzle extends 6 inches or more from Date of original test 00–0000
shell of tank, a V-shaped breakage groove shall be cut (not cast) in
Car assembler (if other than tanker builder) DEF
the upper part of the outlet nozzle at a point immediately below the
lowest part of the inside closure seat or plug. In no case may the
nozzle wall thickness at the root of the “V” be more than 1⁄4-inch. (b) [Reserved]
Where the nozzle is not a single piece, provision shall be made for §179.101@Individual specification requirements applicable to
the equivalent of the breakage groove. The nozzle must be of a thick- pressure tank car tanks.
ness to insure that accidental breakage will occur at or below the “V”
groove or its equivalent. On cars without continuous center sills, the §179.101–1@Individual specification requirements. In addition to
breakage groove or its equivalent may not be more than 15 inches §179.100, the individual specification requirements are as follows:
594
10/2007 C-III [M-1002] 539

APPENDIX X M-1002
April 2007 §179.101–1—§179.102–4
Bursting pressure Minimum plate Test pressure Manway cover Bottom Reference
DOT specification Insulation (psig) thickness (inches) (psig) thickness outlet Bottom washout (179.***)
2
105A100ALW Yes 500 5/8 100 2 1/2 No No
2
105A200ALW Yes 500 5/8 200 2 1/2 No No
2
105A300ALW Yes 750 5/8 300 2 5/8 No No
3
105A100W Yes 500 9/16 100 2 1/4 No No
3
105A200W Yes 500 9/16 200 2 1/4 No No
1 7
105A300W Yes 750 11/16 300 2 1/4 No No
1 7
105A400W Yes 1,000 11/16 400 2 1/4 No No
1
105A500W Yes 1,250 11/16 500 2 1/4 No No 102–1, 102–2
1
105A600W Yes 1,500 11/16 600 2 1/4 No No 102–4, 102–17
2
109A100ALW Optional 500 5/8 100 2 1/2 No Optional
2
2
1
109A300W Optional 500 11/16 300 2 1/4 No Optional
112A200W Optional4 500 35
9/16 200 2 1/4 No No
11/16 340 2 1/4 No No
112A400W Optional4 1,000 1
11/16 400 2 1/4 No No
112A500W Optional4 1,250 1
11/16 500 2 1/4 No No
11/16 340 6
Optional Optional 103
114A400W Optional4 1,000 1
11/16 400 6
Optional Optional 103
2
120A200ALW Yes 500 5/8 200 2 1/2 Optional Optional 103
3
120A100W Yes 500 9/16 100 2 1/4 Optional Optional 103
3
1
1
120A400W Yes 1,000 11/16 400 2 1/4 Optional Optional 103
1
120A500W Yes 1,250 11/16 500 2 1/4 Optional Optional 103
1
When steel of 65,000 to 81,000 p.s.i. minimum tensile strength is used, the thickness of plates shall be not less than 5/8 inch, and when steel of 81,000 p.s.i. minimum tensile strength
is used, the minimum thickness of plate shall be not less than 9/16 inch.
2
When approved material other than aluminum alloys are used, the thickness shall be not less than 2 1/4 inches.
3
When steel of 65,000 p.s.i. minimum tensile strength is used, minimum thickness of plates shall be not less than 1/2 inch.
4
Tank cars not equipped with a thermal protection or an insulation system used for the transportation of a Class 2 (compressed gas) material must have at least the upper two–thirds of
the exterior of the tank, including manway nozzle and all appurtenances in contact with this area, finished with a reflective coat of white paint.
5
For inside diameter of 87 inches or less, the thickness of plates shall be not less than 1/2 inch.
6
See AAR Specifications for Tank Cars, appendix E, E4.01 (IBR, see §171.7 of this subchapter), and §179.103–2.
7
When the use of nickel is required by the lading, the thickness shall not be less than two inches.
§179.102@Special commodity requirements for pressure tank car vinyl fluoride, inhibited, must comply with the following special require-
tanks. (a) In addition to §§179.100 and 179.101 the following re- ments:
quirements are applicable: (a) All plates for the tank must be fabricated of material listed in
(b) [Reserved] paragraph (a)(2) of this section, and appurtenances must be fabri-
cated of material listed in paragraph (a)(1) or (a)(2) of this section.
§179.102–1@Carbon dioxide, refrigerated liquid. (a) Tank cars (1) Stainless steel, ASTM A 240/A 240M (IBR, see §171.7 of this
used to transport carbon dioxide, refrigerated liquid must comply with subchapter), Type 304, 304L, 316 or 316L, in which case impact tests
the following special requirements: are not required; or
(1) All plates for tank, manway nozzle and anchorage of tanks must (2) Steel complying with ASTM Specification A 516 (IBR, see §171.7
be made of carbon steel conforming to ASTM A 516/A 516M (IBR, of this subchapter); Grade 70; ASTM Specification A 537 (IBR, see
see §171.7 of this subchapter), Grades 55, 60, 65, or 70, or AAR §171.7 of this subchapter), Class 1; or AAR Specification TC 128,
Specification TC 128–78, Grade B. The ASTM A 516/A 516M plate Grade B, in which case impact tests must be performed as follows:
must also meet the Charpy V-Notch test requirements of ASTM A 20/ (i) ASTM A 516/A 516M and A 537/A 537M material must meet
A 20M (see table 16) (IBR, see §171.7 of this subchapter) in the the Charpy V-Notch test requirements, in longitudinal direction
longitudinal direction of rolling. The TC 128 plate must also meet the of rolling, of ASTM A 20/A 20M (IBR, see §171.7 of this sub-
Charpy V-Notch energy absorption requirements of 15 ft.-lb. minimum chapter).
average for 3 specimens, and 10 ft.-lb. minimum for one specimen, (ii) AAR Specification TC 128 material must meet the Charpy V-
at minus 50°F in the longitudinal direction of rolling in accord with Notch test requirements, in longitudinal direction of rolling, of
ASTM A 370 (IBR, see §171.7 of this subchapter). Production-welded 15 ft.-lb. minimum average for 3 specimens, with a 10 ft.-lb.
test plates prepared as required by W4.00 of AAR Specifications for minimum for any one specimen, at minus 50°F or colder, in
Tank Cars, appendix W (IBR, see §171.7 of this subchapter), must accordance with ASTM A 370 (IBR, see §171.7 of this sub-
include impact test specimens of weld metal and heat-affected zone. chapter).
As an alternate, anchor legs may be fabricated of stainless steel, (iii) Production welded test plates must—
ASTM A 240/A 240M Types 304, 304L, 316 or 316L, for which impact (A) Be prepared in accordance with AAR Specifications for
tests are not required. Tank Cars, appendix W, W4.00 (IBR, see §171.7 of this
(2)–(6) [Reserved] subchapter);
(b) [Reserved] (B) Include impact specimens of weld metal and heat affected
zone prepared and tested in accordance with AAR Specifi-
§179.102–2@Chlorine. (a) Each tank car used to transport chlorine cations for Tank Cars, appendix W, W9.00; and
must comply with all of the following: (C) Meet the same impact requirements as the plate material.
(1) Tanks must be fabricated from carbon steel complying with (b) Insulation must be of approved material.
ASTM Specification A 516 (IBR, see §171.7 of this subchapter), Grade (c) Excess flow valves must be installed under all liquid and vapor
70, or AAR Specification TC 128, Grade A or B. valves, except safety relief valves.
(2)–(3) [Reserved] (d) A thermometer well may be installed.
(b) [Reserved] (e) Only an approved gaging device may be installed.
(f) A pressure gage may be installed.
§179.102–4@Vinyl fluoride, stabilized. Each tank used to transport (g) Aluminum, copper, silver, zinc, or an alloy containing any of
595
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M-1002 APPENDIX X
§179.102–4—§179.103–5 April 2007
these metals may not be used in the tank construction, or in fittings §179.103–1@Type. (a) Tanks built under this section may be of any
in contact with the lading. approved cross section.
(h) The jacket must be stenciled, adjacent to the water capacity (b) Any portion of the tank shell not circular in cross section shall
stencil, have walls of such thickness and be so reinforced that the stresses
MINIMUM OPERATING TEMPERATURE °F. in the walls caused by a given internal pressure are no greater than
the circumferential stresses which would exist under the same internal
(i) The tank car and insulation must be designed to prevent the pressure in the wall of a tank of circular cross section designed in
vapor pressure of the lading from increasing from the pressure at the accordance with paragraphs §179.100–6(a) and (b), but in no case
maximum allowable filling density to the start-to-discharge pressure shall the wall thickness be less than that specified in §179.101.
of the reclosing pressure relief valve within 30 days, at an ambient (c) [Reserved]
temperature of 90°F. (d) Valves and fittings need not be mounted on the manway cover.
(e) One opening may be provided in each head for use in purging
§179.102–17@Hydrogen chloride, refrigerated liquid. Each tank
the tank interior.
car used to transport hydrogen chloride, refrigerated liquid must com-
ply with the following special requirements.
§179.103–2@Manway cover. (a) The manway cover must be an
(a) The tank car must comply with Specification DOT–105J600W
approved design.
and be designed for loading at minus 50°F or colder.
(b) If no valves or measuring and sampling devices are mounted
(b) All plates for the tank must be fabricated of material listed in
on manway cover, no protective housing is required.
paragraph (b)(2) of this section, and appurtenances must be fabri-
cated of material listed in paragraph (b)(1) or (b)(2) of this section §179.103–3@Venting, loading and unloading valves, measuring
(1) Stainless steel, ASTM A 240/A 240M (IBR, see §171.7 of this and sampling devices. (a) Venting, loading and unloading valves,
subchapter), Type 304, 304L, 316, or 316L, in which case impact measuring and sampling devices, when used, shall be attached to a
tests are not required; or nozzle or nozzles on the tank shell or heads.
(2) Steel conforming to ASTM A 516/A 516M (IBR, see §171.7 of (b) These valves and appurtenances must be grouped in one loca-
this subchapter), Grade 70; ASTM A 537/A 537M, (IBR, see §171.7 tion and, except as provided in §179.103–5, must be equipped with
of this subchapter) Class 1; or AAR Specification TC 128, Grade B a protective housing with cover, or may be recessed into tank shell
in which case impact tests must be performed as follows: with cover. An additional set grouped in another location may be
(i) ASTM A 516/A 516M and A 537/A 537M material must meet provided. Protective housing with cover, when used, must have steel
the Charpy V-notch test requirements, in longitudinal direction sidewalls not less than three-fourths inch in thickness and a metal
of rolling, of ASTM A 20/A 20M (IBR, see §171.7 of this sub- cover not less than one-fourth inch in thickness that can be securely
chapter). closed. Underframe sills are an acceptable alternate to the protective
(ii) AAR Specification TC 128 material must meet the Charpy V- housing cover, provided the arrangement is of approved design. For
notch test requirements, in longitudinal direction of rolling of fittings recessed into tank shell, protective cover must be metal and
15 ft.-lb. minimum average for 3 specimens, with a 10 ft.-lb. not less than one-fourth inch in thickness.
minimum for any one specimen, at minus 50°F or colder, in (c) When tank car is used to transport liquefied flammable gases,
accordance with ASTM A 370 (IBR, see §171.7 of this sub- the interior pipes of the loading, unloading, and sampling valves must
chapter). be equipped with excess flow valves of approved design except when
(iii) Production welded test plates must— quick closing internal valves of approved design are used. When the
(A) Be prepared in accordance with AAR Specifications for interior pipe of the gaging device provides a means of the passage
Tank Cars, appendix W, W4.00 (IBR, see §171.7 of this of lading from the interior to the exterior of the tank, it must be equipped
subchapter); with an excess flow valve of approved design or with an orifice not
(B) include impact test specimens of weld metal and heat af- exceeding 0.060 inch.
fected zone prepared and tested in accordance with AAR
Specifications for Tank Cars, appendix W, W9.00; and §179.103–4@Safety relief devices and pressure regulators.
(C) meet the same impact requirements as the plate material. (a) Safety relief devices and pressure regulators must be located
(c) Insulation must be of approved material. on top of the tank near the center of the car on a nozzle, mounting
(d) Pressure relief valves must be trimmed with monel or other plate or recess in the shell. Through or stud bolts, if used, must not
approved material and equipped with a rupture disc of silver, polyte- enter the tank.
trafluoroethylene coated monel, or tantalum. Each safety relief device (b) Metal guard of approved design must be provided to protect
shall have the space between the rupture disc and the valve vented safety relief devices and pressure regulators from damage.
with a suitable auxiliary valve. The discharge from each pres- §179.103–5@Bottom outlets. (a) In addition to or in place of the
sure relief valve must be directed outside the protective housing. venting, loading and unloading valves, measuring and sampling de-
(e) Loading and unloading valves must be trimmed with Hastelloy vices as prescribed in §179.103–3, tanks may be equipped with ap-
B or C, monel, or other approved material, and identified as “Vapor” proved bottom outlet valves. If applied, bottom outlet valves must
or “Liquid”. Excess flow valves must be installed under all liquid and meet the following requirements:
vapor valves, except safety relief valves. (1) On cars with center sills, a ball valve may be welded to the
(f) A thermometer well may be installed. outside bottom of the tank or mounted on a pad or nozzle with a
(g) Only an approved gaging device may be installed. tongue and groove or male and female flange attachment, but in no
(h) A sump must be installed in the bottom of the tank under the case shall the breakage groove or equivalent extend below the bottom
liquid pipes. flange of the center sill. On cars without continuous center sills, a ball
(i) All gaskets must be made of, or coated with, polytetrafluoroethy- valve may be welded to the outside bottom of the tank or mounted
lene or other approved material. with a tongue and groove or male and female flange attachment on
(j) The tank car tank may be equipped with exterior cooling coils a pad attached to the outside bottom of the tank. The mounting pad
on top of the tank car shell. must have a maximum thickness of 21⁄2 inches measured on the longi-
(k) The jacket must be stenciled, adjacent to the water capacity tudinal centerline of the tank. The valve operating mechanism must
stencil, be provided with a suitable locking arrangement to insure positive
MINIMUM OPERATING TEMPERATURE °F. closure during transit.
(2) When internal bottom outlet valve is used in liquefied flammable
(l) The tank car and insulation must be designed to prevent the gas service, the outlet of the valve must be equipped with an excess
pressure of the lading from increasing from the pressure at the maxi- flow valve of approved design, except when a quick-closing internal
mum allowable filling density to the start-to-discharge pressure of the valve of approved design is used. Protective housing is not required.
pressure relief valve within 30 days, at an ambient temperature of 90°F. (3) Bottom outlet must be equipped with a liquid tight closure at
its lower end.
§179.103@Special requirements for class 114A *** tank car tanks. (b) Bottom outlet equipment must be of approved design and must
(a) In addition to the applicable requirements of §§179.100 and meet the following requirements:
179.101 the following requirements shall be complied with: (1) The extreme projection of the bottom outlet equipment may not
(b) [Reserved] be more than allowed by appendix E of the AAR Specifications for
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APPENDIX X M-1002
April 2007 §179.103–5—§179.200–6
Tank Cars (IBR, see §171.7 of this subchapter). All bottom outlet minimum 1-inch auxiliary test valve with a threaded closure
reducers and closures and their attachments shall be secured to the may be substituted for the 1-inch pipe plug (see Fig E17.6). If
car by at least 3⁄8 inch chain, or its equivalent, except that bottom the threaded cap closure does not have a pipe plug or integral
outlet closure plugs may be attached by 1⁄4 inch chain. When the auxiliary test valve, a minimum 1-inch NPT pipe plug shall be
bottom outlet closure is of the combination cap and valve type, the installed in the outlet nozzle above the closure (see Fig. E17.7).
pipe connection to the valve shall be closed by a plug, cap, or ap- (iv) A two-piece quick-coupling device using a clamped dust cap
proved quick coupling device. The bottom outlet equipment should must include an in-line auxiliary valve, either integral with the
include only the valve, reducers and closures that are necessary for quick-coupling device or located between the primary bottom
the attachment of unloading fixtures. The permanent attachment of outlet valve and the quick-coupling device. The quick-coupling
supplementary exterior fittings must be approved by the AAR Commit- device closure dust cap or outlet nozzle shall be fitted with a
tee on Tank Cars. minimum 1-inch NPT closure (see Fig. E17.8 and E17.9).
(2) To provide for the attachment of unloading connections, the (3) The valve operating mechanism must be provided with a suit-
discharge end of the bottom outlet nozzle or reducer, the valve body able locking arrangement to insure positive closure during transit.
of the exterior valve, or some fixed attachment thereto, shall be pro- (4) If the outlet nozzle extends 6 inches or more from shell of tank,
vided with one of the following arrangements or an approved modifica- a V-shaped breakage groove shall be cut (not cast) in the upper part
tion thereof. (See appendix E. Fig. E17 of the AAR Specifications for to the outlet nozzle at a point immediately below the lowest part of
Tank Cars for illustrations of some of the possible arrangements.) valve closest to the tank. In no case may the nozzle wall thickness at
(i) A bolted flange closure arrangement including a minimum 1- the roof of the “V” be more than 1⁄4-inch. On cars without continuous
inch NPT pipe plug (see Fig. E17.1) or including an auxiliary center sills, the breakage groove or its equivalent may not be more
valve with a threaded closure. than 15 inches below the tank shell. On cars with continuous center
(ii) A threaded cap closure arrangement including a minimum 1- sills, the breakage groove or its equivalent must be above the bottom
inch NPT pipe plug (see Fig. E17.2) or including an auxiliary of the center sill construction.
valve with a threaded closure. (5) The valve body must be of a thickness which will insure that
(iii) A quick-coupling device using a threaded plug closure of at accidental breakage of the outlet nozzle will occur at or below the “V”
least 1-inch NPT or having a threaded cap closure with a mini- groove, or its equivalent, and will not cause distortion of the valve
mum 1-inch NPT pipe plug (see Fig. E17.3 through E17.5). A seat or valve.
Subpart D
SPECIFICATIONS FOR NON-PRESSURE TANK CAR TANKS
(Classes DOT-111AW, and 115AW)
§179.200@General specifications applicable to non-pressure tank be not less than specified in §179.201–1, nor that calculated by the
car tanks (Classes DOT-111). following formula:
§179.200–1@Tanks built under these specifications must meet Pd

t= × 1.83
the requirements of §§179.200 and 179.201. 2SE
Where:
§179.200–3@Type. Tank built under these specifications must be
circular in cross section, with formed heads designed convex outward. d =
Inside diameter in inches;
When specified in §179.201–1, the tank must have at least one manway E =
0.9 Welded joint efficiency; except E = 1.0 for seamless heads;
or one expansion dome with manway, and such other external projec- P =
Minimum required bursting pressure in psig;
tions as are prescribed herein. When the tank is divided into compart- S =
Minimum tensile strength of plate material in p.s.i. as prescribed
ments, each compartment must be treated as a separate tank. in §179.200–7;
t = Minimum thickness of plate in inches after forming.
§179.200–4@Insulation. (a) If insulation is applied, the tank shell
and expansion dome when used must be insulated with an approved (c) The wall thickness after forming of a flanged and dished head
material. The entire insulation must be covered with a metal jacket of a must be not less than specified in §179.201–1, nor that calculated by
thickness not less than 11 gauge (0.1196 inch) nominal (Manufacturer’s the following formula:
Standard Gauge) and flashed around all openings so as to be weather 5PL
tight. The exterior surface of a carbon steel tank and the inside surface t=
6SE
of a carbon steel jacket must be given a protection coating.
(b) If insulation is a specification requirement, it shall be of sufficient Where:
thickness so that the thermal conductance at 60°F is not more than E = 0.9 Welded joint efficiency; except E = 1.0 for seamless
0.225 Btu. per hour, per square foot, per degree F temperature differ- heads;
ential, unless otherwise provided in §179.201–1. If exterior heaters L = Main inside radius to which head is dished, measured on
are attached to tank, the thickness of the insulation over each heater concave side in inches;
element may be reduced to one-half that required for the shell. P = Minimum required bursting pressure in psig;
S = Minimum tensile strength of plate material in p.s.i. as pre-
scribed in §179.200–7;
§179.200–6@Thickness of plates. (a) The wall thickness after t = minimum thickness of plate in inches after forming.
forming of the tank shell, dome shell, and of 2:1 ellipsoidal heads
must be not less than specified in §179.201–1, nor that calculated by (d) If plates are clad with material having tensile strength properties
the following formula: at least equal to the base plate, the cladding may be considered a
part of the base plate when determining thickness. If cladding material
Pd
t= does not have tensile strength at least equal to the base plate, the
2SE base plate alone must meet the thickness requirements.
Where: (e) For a tank constructed of longitudinal sections, the minimum
width of bottom sheet of the tank must be 60 inches measured on the
d = Inside diameter in inches; arc, but in all cases the width must be sufficient to bring the entire
E = 0.9 Welded joint efficiency; except E = 1.0 for seamless heads; width of the longitudinal welded joint, including welds, above the
P = Minimum required bursting pressure in psig; bolster.
S = Minimum tensile strength of plate material in p.s.i. as prescribed (f) For a tank built of one piece cylindrical sections, the thickness
in §179.200–7; specified for bottom sheet must apply to the entire cylindrical section.
t = Minimum thickness of plate in inches after forming. (g) See §179.200–9 for thickness requirements for a compart-
(b) The wall thickness after forming of 3:1 ellipsoidal heads must mented tank.
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M-1002 APPENDIX X
§179.200–7—§179.200–13 April 2007
§179.200–7@Materials. (a) Plate material used to fabricate the tank the following specification (IBR, see §171.7 of this subchapter):
and, when used, expansion dome or manway nozzle material, must
Minimum elongation in 2
meet one of the following specifications with the indicated minimum Minimum tensile strength inches (percent) weld
tensile strength and elongation in the welded condition. Specifications (p.s.i.) welded condition1 metal (longitudinal)
(b) Carbon steel plate: The maximum allowable carbon content ASTM A 302 Gr. B 80,000 20
must be 0.31 percent when the individual specification allows carbon 1
Maximum stresses to be used in calculations.
content greater than this amount. The plates may be clad with other
approved materials: (g) All parts and items of construction in contact with the lading
must be made of material compatible with plate material and not
Minimum tensile strength inches (percent) weld
subject to rapid deterioration by the lading, or be coated or lined with
Specifications (p.s.i.) welded condition 1 metal (longitudinal) suitable corrosion resistant material.
AAR TC 128, Gr. B 81,000 19 (h) All external projections that may be in contact with the
lading and all castings, forgings, or fabrications used for fittings
ASTM A 5162 70,000 20
1
or attachments to tank and expansion dome, when used, in contact
Maximum stresses to be used in calculations. with lading must be made of material to an approved specification.
2
This specification is incorporated by reference (IBR, see §171.7 of this subchapter).
See AAR Specifications for Tank Cars, appendix M, M4.05 (IBR,
(c) Aluminum alloy plate: Aluminum alloy plate must be suitable see §171.7 of this subchapter) for approved material specifications
for welding and comply with one of the following specifications (IBR, for castings for fittings.
see §171.7 of this subchapter):
§179.200–8@Tank heads. (a) All external tank heads must be an
Minimum elongation in 2 ellipsoid of revolution in which the major axis must equal the diameter
Minimum tensile strength inches (percent) 0 temper of the shell and the minor axis must be one-half the major axis.
Specifications (p.s.i.) welded condition 3 4 weld metal (longitudinal)
(b) Internal compartment tank heads may be 2:1 ellipsoidal, 3:1
ASTM B 209, Alloy 50521 25,000 18
ellipsoidal, or flanged and dished to thicknesses as specified in
ASTM B 209, Alloy 50832 38,000 16 §179.200–6. Flanged and dished heads must have main inside radius
ASTM B 209, Alloy 50861 35,000 14 not exceeding 10 feet, and inside knuckle radius must not be less
ASTM B 209, Alloy 51541 30,000 18 than 33⁄4 inches for steel, alloy steel, or nickel tanks, and not less than
ASTM B 209, Alloy 52541 30,000 18
5 inches for aluminum alloy tanks.
ASTM B 209, Alloy 54541 31,000 18 §179.200–9@Compartment tanks. (a) When a tank is divided
ASTM B 209, Alloy 56521 25,000 18 into compartments, by inserting interior heads, interior heads must
1
For fabrication, the parent plate material may be 0, H112, or H32 temper, but design
be inserted in accordance with AAR Specifications for Tank Cars,
calculations must be based on minimum tensile strength shown. appendix E, E7.00 (IBR, see §171.7 of this subchapter), and must
2
3
0 temper only. comply with the requirements specified in §179.201–1. Voids be-
Weld filler metal 5556 must not be used. tween compartment heads must be provided with at least one
4
Maximum stress to be used in calculations.
tapped drain hole at their lowest point, and a tapped hole at the
(d) High alloy steel plate: High alloy steel plate must comply with top of the tank. The top hole must be closed, and the bottom hole
one of the following specifications: may be closed, with not less than three-fourths inch and not more
than 11⁄2-inch solid pipe plugs having NPT threads.
Minimum tensile strength inches (percent) weld (b) When the tank is divided into compartments by constructing
Specifications (p.s.i.) welded condition 1 metal (longitudinal) each compartment as a separate tank, these tanks shall be joined
ASTM A 240/A 240M (incor- 75,000 30 together by a cylinder made of plate, having a thickness not less
porated by reference; see than that required for the tank shell and applied to the outside
§171.7 of this subchapter), surface of tank head flanges. The cylinder shall fit the straight
Type 304
flange portion of the compartment tank head tightly. The cylinder
ASTM A 240/A 240M (incor- 70,000 30 shall contact the head flange for a distance of at least two times
porated by reference; see
§171.7 of this subchapter), the plate thickness, or a minimum of 1 inch, whichever is greater.
Type 304L The cylinder shall be joined to the head flange by a full fillet weld.
ASTM A 240/A 240M (incor- 75,000 30 Distance from head seam to cylinder shall not be less than 11⁄2
porated by reference; see inches or three times the plate thickness, whichever is greater.
§171.7 of this subchapter), Voids created by the space between heads of tanks joined together
Type 316
to form a compartment tank shall be provided with a tapped drain
ASTM A 240/A 240M (incor- 70,000 30 hole at their lowest point and a tapped hole at top of tank. The
§171.7 of this subchapter), top hole shall be closed and the bottom hole may be closed with
Type 316L solid pipe plugs not less than 3⁄4 inch nor more than 11⁄2 inches
1
Maximum stresses to be used in calculations. having NPT threads.
2
High alloy steel materials used to fabricate tank and expansion dome, when used, must
be tested in accordance with Practice A of ASTM Specification A 262 titled, “Standard §179.200–10@Welding. (a) All joints shall be fusion-welded in com-
Practices for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steels” pliance with the requirements of AAR Specifications for Tank Cars,
(IBR; see §171.7 of this subchapter). If the specimen does not pass Practice A, Practice B appendix W (IBR, see §171.7 of this subchapter). Welding procedures,
or C must be used and the corrosion rates may not exceed the following:
welders and fabricators shall be approved.
Test procedures Material Corrosion rate i.p.m. (b) Welding is not permitted on or to ductile iron or malleable iron
Practice B Types 304, 304L, 316, and 316L 0.0040
fittings.
Practice C Type 304L .0020 §179.200–11@Postweld heat treatment. When specified in
Type 304L and Type 316L test specimens must be given a sensitizing treatment prior to §179.201–1, after welding is complete, postweld heat treatment must
testing. (A typical sensitizing treatment is 1 hour at 1250°F.) be in compliance with the requirements of AAR Specifications for Tank
Cars, appendix W (IBR, see §171.7 of this subchapter).
(e) Nickel plate: Nickel plate must comply with the following specifi-
cation (IBR, see §171.7 of this subchapter): §179.200–13@Manway ring or flange, pressure relief device
flange, bottom outlet nozzle flange, bottom washout nozzle flange
Minimum tensile strength inches (percent) weld and other attachments and openings. (a) These attachments shall
Specifications (p.s.i.) welded condition1 metal (longitudinal) be fusion welded to the tank and reinforced in an approved manner
ASTM B 162 2 40,000 20 in compliance with the requirements of appendix E, figure 10, of the
1
AAR Specifications for Tank Cars (IBR, see §171.7 of this subchapter).
2
When used as cladding for carbon steel plate, low-carbon nickel is required. (b) The opening in the manway ring must be at least 16 inches in
diameter except that acid resistant lined manways must be at least
(f) Manganese-molybdenum steel plate: Manganese-molybde- 18 inches in diameter before lining.
num steel plate must be suitable for fusion welding and comply with (c) The manway ring or flange, shall be made of cast, forged or
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APPENDIX X M-1002
April 2007 §179.200–13—§179.200–17
fabricated metal. The metal of the dome, tank, or nozzle must be shall be made for closing pipe connections of valves.
compatible with the manway ring or flange, so that they may be welded (c) A tank may be equipped with a vacuum relief valve of an ap-
together. proved design. Protective housing is not required.
(d) The openings for the manway or other fittings shall be reinforced (d) When using a visual guaging device on a car with a hinged
in an approved manner. manway cover, an outage scale visible through the manway opening
shall be provided. If loading devices are applied to permit tank loading
§179.200–14@Expansion capacity. (a) Tanks shall have expan- with cover closed, a telltale pipe may be provided. Telltale pipe shall
sion capacity as prescribed in this subchapter. This capacity shall be capable of determining that required outage is provided. Pipe shall
be provided in the tank for Class DOT–111A cars, or in a dome for be equipped with 1⁄4 inch minimum NPT control valve mounted outside
Class DOT–103 and 104 type cars. tank and enclosed within a housing. Other approved devices may be
(b) For tanks having an expansion dome, the expansion capacity used in lieu of outage scale or telltale pipe.
is the total capacity of the tank and dome combined. The capacity (e) Bottom of tank shell may be equipped with a sump or siphon
of the dome shall be measured from the inside top of shell of tank to bowl, or both, welded or pressed into the shell. Such sumps or
the inside top of dome or bottom of any vent pipe projecting inside siphon bowls, if applied, are not limited in size and must be made
of dome, except that when a pressure relief device is applied to side of cast, forged, or fabricated metal. Each sump or siphon bowl
of dome, the effective capacity of the dome shall be measured from must be of good welding quality in conjunction with the metal of
top of the pressure relief device opening inside of dome to inside top the tank shell. When sump or siphon bowl is pressed in the bottom
of shell of tank. of the tank shell, the wall thickness of the pressed section must
(c) The opening in the tank shell within the dome shall be at least not be less than that specified for the shell. The section of a circular
29 inches in diameter. When the opening in the tank shell exceeds cross section tank to which a sump or siphon bowl is attached
30 inches in diameter, the opening shall be reinforced in an approved need not comply with the out-of-roundness requirement specified
manner. This additional reinforcement may be accomplished by the in appendix W, W14.06, of the AAR Specifications for Tank Cars.
use of a dome opening of the flued-type as shown in appendix E, Any portion of a sump or siphon bowl not forming a part of a
Figure E 10C of the AAR Specifications for Tank Cars or by the use cylinder of revolution must have walls of such thickness and be
of reinforcing as outlined in Appendix E, E3.04 and Figures E10K and so reinforced that the stresses in the walls caused by a given
E10L. When the opening in the tank shell is less than the inside internal pressure are not greater than the circumferential stress
diameter of the dome, and the dome pocket is not closed off in an which would exist under the same internal pressure in the wall of
approved manner, dome pocket drain holes shall be provided in the a tank of circular cross section designed in accordance with
tank shell with nipples projecting inside the tank at least 1 inch. §179.200–6(a) and (d). In no case shall the wall thickness be less
(d) The dome head shall be of approved contour and shall be than that specified in §179.201–1.
designed for pressure on concave side. (f) When top loading and discharge devices, or venting and air
(e) Aluminum alloy domes: inlet devices are installed with exposed piping to a removed location,
(1) The dome shell thickness shall be calculated by the formula in shutoff valves must be applied directly to reinforcing pads or nozzles
§179.200–6(a). at their communication through the tank shell, and must be enclosed
(2) The dome head may be an ellipsoid of revolution in which the in a protective housing with provision for a seal. The piping must
major axis shall be equal to the diameter of the dome shell and the include breakage grooves, and suitable bracing. Relief valves must
minor axis shall be one-half the major axis. The thickness in this case be applied to liquid lines for protection in case lading is trapped.
shall be determined by using formula in §179.200–6(a). Provision must be made to insure closure of the valves while the
(3) The dome head, if dished, must be dished to a radius not car is in transit.
exceeding 96 inches. Thickness of dished dome head must be calcu- (g) Protective housing, when required, must be fabricated of ap-
lated by the formula in §179.200–6(c). proved material and have cover and sidewalls not less than 0.119
(4) Tank shell shall be reinforced by the addition of a plate equal inch in thickness.
to or greater than shell in thickness and the cross sectional area
shall exceed metal removed for dome opening, or tank shell shall be §179.200–17@Bottom outlets. (a) If indicated in §179.201–1, tank
reinforced by a seamless saddle plate equal to or greater than shell may be equipped with bottom outlet. Bottom outlet, if applied, must com-
in thickness and butt welded to tank shell. The reinforcing saddle ply with the following requirements:
plate shall be provided with a fluid opening having a vertical flange (1) The extreme projection of the bottom outlet equipment may
of the diameter of the dome for butt welding shell of dome to the not be more than that allowed by appendix E of the AAR Specifica-
flange. The reinforcing saddle plate shall extend about the dome a tions for Tank Cars (IBR, see §171.7 of this subchapter). All bottom
distance measured along shell of tank at least equal to the extension outlet reducers and closures and their attachments shall be secured
at top of tank. Other approved designs may be used. to the car by at least 3⁄8-inch chain, or its equivalent, except that
the bottom outlet closure plugs may be attached by 1⁄4-inch chain.
§179.200–15@Closures for manways. (a) Manway covers must When the bottom outlet closure is of the combination cap and valve
be of approved type. type, the pipe connection to the valve shall be closed by a plug,
(b) Manway covers shall be designed to provide a secure closure cap, or approved quick coupling device. The bottom outlet equip-
of the manway. ment should include only the valve, reducers and closures that are
(c) Manway covers must be of approved cast, forged, or fabricated necessary for the attachment of unloading fixtures. The permanent
metals. Malleable iron, if used, must comply with ASTM A 47 (IBR, attachment of supplementary exterior fittings shall be approved by
see §171.7 of this subchapter), Grade 35018. Cast iron manway covers the AAR Committee on Tank Cars.
must not be used. (2) Bottom outlet must be of approved construction, and be pro-
(d) All joints between manway covers and their seats shall be made vided with a liquid-tight closure at its lower end.
tight against leakage of vapor and liquid by use of gaskets of suitable (3) On cars with center sills, a ball valve may be welded to the
material. outside bottom of the tank or mounted on a pad or nozzle with a
(e) For other manway cover requirements see §179.201–1. tongue and groove or male and female flange attachment. In no
case shall the breakage groove or equivalent extend below the
§179.200–16@Gauging devices, top loading and unloading de- bottom flange of the center sill. On cars without continuous center
vices, venting and air inlet devices. (a) When installed, these sills, a ball valve may be welded to the outside bottom of the tank
devices shall be of an approved design which will prevent inter- or mounted with a tongue and groove or male and female flange
change with any other fixture, and be tightly closed. Unloading attachment on a pad attached to the outside bottom of the tank.
pipes shall be securely anchored within the tank. Each tank or The mounting pad must have a maximum thickness of 21⁄2 inches
compartment may be equipped with one separate air connection. measured on the longitudinal centerline of the tank. The valve
(b) When the characteristics of the commodity for which the car operating mechanism must be provided with a suitable locking
is authorized are such that these devices must be equipped with arrangement to insure positive closure during transit.
valves or fittings to permit the loading and unloading of the contents, (4) The valve operating mechanism for valves applied to the interior
these devices, including valves, shall be of an approved design, of the tank, and outlet nozzle construction, must insure against the
and be provided with a protective housing except when plug or unseating of the valve due to stresses or shocks incident to transpor-
ball type valves with operating handles removed are used. Provision tation.
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C-III [M-1002] 544 10/2007

M-1002 APPENDIX X
§179.200–17—§179.201–1 April 2007
(5) Bottom outlet nozzle of interior valves and the valve body of or below the “V” groove or its equivalent. On cars without continuous
exterior valves, must be of cast, fabricated, or forged metal. If welded center sills, the breakage groove or its equivalent may not be more
to tank, they must be of good weldable quality in conjunction with than 15 inches below the outer shell. On cars with continuous
metal of tank. center sills, the breakage groove or its equivalent must be above
(6) To provide for the attachment of unloading connections, the the bottom of the center sill construction.
discharge end of the bottom outlet nozzle or reducer, the valve body (4) The closure plug and seat must be readily accessible or remov-
of the exterior valve, or some fixed attachment thereto, shall be pro- able for repairs, including grinding.
vided with one of the following arrangements or an approved modifica- (5) The closure of the washout nozzle must be equipped with a
3
tion thereof. (See appendix E, Fig. E17 of the AAR Specifications for ⁄4-inch solid screw plug. Plug must be attached by at least a 1⁄4-
Tank Cars for illustrations of some of the possible arrangements.) inch chain.
(i) A bolted flange closure arrangement including a minimum 1- (6) Joints between closures and their seats may be gasketed with
inch NPT pipe plug (see Fig. E17.1) or including an auxiliary suitable material.
valve with a threaded closure.
§179.200–19@Reinforcements, when used, and appurtenances
(ii) A threaded cap closure arrangement including a minimum 1-
not otherwise specified. (a) All attachments to tank and dome shall
inch NPT pipe plug (see Fig. E17.2) or including an auxiliary
be applied by approved means. Rivets if used shall be caulked inside
valve with a threaded closure.
and outside.
(iii) A quick-coupling device using a threaded plug closure of at (b) Reinforcing pads must be used between external brackets
least 1-inch NPT or having a threaded cap closure with a mini- and shells if the attachment welds exceed 6 lineal inches of 1⁄4-
mum 1-inch NPT pipe plug (see Fig. E17.3 through E17.5). A inch fillet or equivalent weld per bracket or bracket leg. When
minimum 1-inch auxiliary test valve with a threaded closure reinforcing pads are used, they must not be less than one-fourth
may be substituted for the 1-inch pipe plug (see Fig. E17.6). inch in thickness, have each corner rounded to a 1 inch minimum
If the threaded cap closure does not have a pipe plug or integral radius, and be attached to the tank by continuous fillet welds
auxiliary test valve, a minimum 1-inch NPT pipe plug shall be except for venting provisions. The ultimate shear strength of the
installed in the outlet nozzle above the closure (see Fig. E17.7). bracket to reinforcing pad weld must not exceed 85 percent of the
(iv) A two-piece quick-coupling device using a clamped dust cap ultimate shear strength of the reinforcing pad to tank weld.
must include an in-line auxiliary valve, either integral with the
quick-coupling device or located between the primary bottom §179.200–21@Closures for openings. (a) All plugs shall be solid,
outlet valve and the quick-coupling device. The quick-coupling with NPT threads, and shall be of a length which will screw at
device closure dust cap or outlet nozzle shall be fitted with a least 6 threads inside the face of fitting or tank. Plugs, when inserted
minimum 1-inch NPT closure (see Fig. E17.8 and E17.9). from the outside of tank heads, shall have the letter “S” at least
3
(7) If the outlet nozzle extends 6 inches or more from the shell of the ⁄8 inch in size stamped with steel stamp or cast on the outside
tank, a V-shaped breakage groove shall be cut (not cast) in the upper surface to indicate the plug is solid.
part of the outlet nozzle at a point immediately below the lowest part of (b) [Reserved]
valve closest to the tank. In no case may the nozzle wall thickness at
§179.200–22@Test of tanks. (a) Each tank shall be tested by com-
the root of the “V” be more than 1⁄4 inch. The outlet nozzle on interior
pletely filling the tank and dome or nozzles with water, or other liquid
valves or the valve body on exterior valves may be steam jacketed, in
having similar viscosity, of a temperature which shall not exceed
which case the breakage groove or its equivalent must be below the
100°F. during the test; and applying the pressure prescribed in
steam chamber but above the bottom of center sill construction. If the
§179.201–1. Tank shall hold the prescribed pressure for at least 10
outlet nozzle is not a single piece, or if exterior valves are applied, provi-
minutes without leakage or evidence of distress. All rivets and closures,
sions shall be made for the equivalent of the breakage groove. On cars
except safety relief valves or safety vents, shall be in place when test
without continuous center sills, the breakage groove or its equivalent
is made.
must be no more than 15 inches below the tank shell. On cars with contin-
(b) Insulated tanks shall be tested before insulation is applied.
uous center sills, the breakage groove or its equivalent must be above
(c) Rubber-lined tanks shall be tested before rubber lining is ap-
the bottom of the center sill construction.
plied.
(8) The flange on the outlet nozzle or the valve body of exterior
(d) Caulking of welded joints to stop leaks developed during the
valves must be of a thickness which will prevent distortion of the valve
foregoing tests is prohibited. Repairs in welded joints shall be made
seat or valve by any change in contour of the shell resulting from
as prescribed in AAR Specifications for Tank Cars, appendix W (IBR,
expansion of lading, or other causes, and which will insure that acci-
see §171.7 of this subchapter).
dental breakage of the outlet nozzle will occur at or below the “V”
groove, or its equivalent. §179.200–23@Tests of pressure relief valves. (a) Each valve shall
(9) The valve must have no wings or stem projecting below the “V” be tested by air or gas for compliance with §179.15 before being put
groove or its equivalent. The valve and seat must be readily accessible into service.
or removable for repairs, including grinding. (b) [Reserved]
(10) The valve operating mechanism on interior valves must have
§179.200–24@Stamping. (a) To certify that the tank complies with
means for compensating for variation in the vertical diameter of the
all specification requirements, each tank shall be plainly and perma-
tank produced by expansion, weight of the liquid contents, or other
nently stamped in letters and figures at least 3⁄8 inch high into the
causes, and may operate from the interior of the tank, but in the event
metal near the center of both outside heads as follows:
the rod is carried through the dome, or tank shell, leakage must be
prevented by packing in stuffing box or other suitable seals and a cap. Example of required stamping
(b) If indicated in §179.201–1, tank may be equipped with bottom
Specification DOT–111A
washout of approved construction. If applied, bottom washout shall
be in accordance with the following requirements: Material ASTM A516–GR 70
(1) The extreme projection of the bottom washout equipment may Cladding material (if any) ASTM A240–304 Clad
not be more than that allowed by appendix E of the AAR Specifications Tank builder’s initials ABC
for Tank Cars. Date of original test 00–0000
(2) Bottom washout shall be of cast, forged or fabricated metal. If
Car assembler (if other than tank builder) DEF
welded to tank, they shall be of good weldable quality in conjunction
with metal of tank. (b) On Class DOT–111 tank cars, the last numeral of the specifica-
(3) If the washout nozzle extends 6 inches or more from the tion number may be omitted from the stamping; for example, DOT–
shell of the tank, a V-shaped breakage groove shall be cut (not 111A100W.
cast) in the upper part of the nozzle at a point immediately below
the lowest part of the inside closure seat or plug. In no case may §179.201@Individual specification requirements applicable to
the nozzle wall thickness at the root of the “V” be more than 1⁄4 non-pressure tank car tanks.
inch. Where the nozzle is not a single piece, provisions shall be
made for the equivalent of the breakage groove. The nozzle must §179.201–1@Individual specification requirements. In addition to
be of a thickness to insure that accidental breakage will occur at §179.200, the individual specification requirements are as follows:
600
10/2007 C-III [M-1002] 545

APPENDIX X M-1002
April 2007 §179.201–1—§179.201–8
Bursting pressure Minimum plate Test pressure References

DOT specification1 Insulation (psig) thickness (inches) (psig) Bottom outlet Bottom washout (179.201–***)
111A60ALW1 Optional 240 ⁄2
1
60 Optional Optional 6(a)
1
60 No Optional
111A60W1 Optional 240 7
⁄16 60 Optional Optional 6(a)
⁄16 60 No Optional
⁄16 60 No No 3, 6(b)
⁄16 60 Optional Optional 4, 5, 6(a), 6(c)
⁄16 60 No No 4, 5, 6(a)
5
100 Optional Optional 6(a)
5
100 No Optional
⁄16 100 No Optional
111A100W3 Yes 500 7
111A100W4 Yes (see 179.201–11) 500 7
⁄16 100 No No 6(a), 8, 10
⁄16 100 No No 3
⁄16 100 Optional Optional 4, 5, 6(a) and 6(c)
⁄16 100 No No 4, 5, 6(c)
1
Tanks marked “ALW” are constructed from aluminum alloy plate; “AN” nickel plate; “CW,” “DW,” “EW,” “W6,” and “W7” high alloy steel or manganese-molybdenum steel plate; and
those marked “BW” or “W5” must have an interior lining that conforms to §179.201-3.
§179.201–2@[Reserved] (f) Polyvinyl chloride lined tanks. Tank car tanks or each compart-
ment thereof may be lined with elastomeric polyvinyl chloride having
§179.201–3@Lined tanks. (a) Rubber-lined tanks. (1) Each tank a minimum lining thickness of three thirty-seconds inch.
or each compartment thereof must be lined with acid-resistant rubber (g) Polyurethane lined tanks. Tank car tanks or each compartment
or other approved rubber compound vulcanized or bonded directly thereof may be lined with elastomeric polyurethane having a minimum
to the metal tank, to provide a nonporous laminated lining, at least lining thickness of one-sixteenth inch.
5
⁄32-inch thick, except overall rivets and seams formed by riveted
attachments in the lining must be double thickness. The rubber lining §179.201–4@Material. All fittings, tubes, and castings and all pro-
must overlap at least 11⁄2 inches at all edges which must be straight jections and their closures, except for protective housing, must also
and be beveled to an angle of approximately 45°, or butted edges meet the requirements specified in ASTM A 262 (IBR, see §171.7 of
of lining must be sealed with a 3-inch minimum strip of lining having this subchapter), except that when preparing the specimen for testing
45° beveled edges. the carburized surface may be finished by grinding or machining.
(2) As an alternate method, the lining may be joined with a skived
butt seam then capped with a separate strip of lining 3 inches wide §179.201–5@Postweld heat treatment and corrosion resis-
having 45° beveled edges. An additional rubber reinforcing pad at tance. (a) Tanks and attachments welded directly thereto must be
least 41⁄2 feet square and at least 1⁄2-inch thick must be applied by postweld heat treated as a unit at the proper temperature except
vulcanizing to the lining on bottom of tank directly under the manway as indicated below. Tanks and attachments welded directly thereto
opening. The edges of the rubber pad must be beveled to an angle fabricated from ASTM A 240/A 240M (IBR, see §171.7 of this subchap-
of approximately 45°. An opening in this pad for sump is permitted. ter) Type 430A, Type 304 and Type 316 materials must be postweld
No lining must be under tension when applied except due to conforma- heat treated as a unit and must be tested to demonstrate that they
tion over rivet heads. Interior of tank must be free from scale, oxidation, possess the corrosion resistance specified in §179.200–7(d), Footnote
moisture, and all foreign matter during the lining operation. 2. Tanks and attachments welded directly thereto, fabricated from
(3) Other approved lining materials may be used provided the mate- ASTM A 240/A 240M Type 304L or Type 316L materials are not re-
rial is resistant to the corrosive or solvent action of the lading in the quired to be postweld heat treated.
liquid or gas phase and is suitable for the service temperatures. (b) Tanks and attachments welded directly thereto, fabricated from
(b) Before a tank car tank is lined with rubber, or other rubber ASTM A 240/A 240M Type 304L and Type 316 materials must be tested
compound, a report certifying that the tank and its equipment have to demonstrate that they possess the corrosion resistance specified in
been brought into compliance with spec. DOT–111A60W5, or §179.200–7(d), Footnote 2.
111A100W5 must be furnished by car owner to the party who is to
apply the lining. A copy of this report in approved form, certifying that §179.201–6@Manways and manway closures. (a) The manway
tank has been lined in compliance with all requirements of one of the cover for spec. DOT–104W, 111A60ALW1, 111A60W1,
above specifications, must be furnished by party lining tank to car 111A100ALW1, 111A100W1, 111A100W3, or 111A100W6 must be
owner. Reports of the latest lining application must be retained by the designed to make it impossible to remove the cover while the interior
car owner until the next relining has been accomplished and recorded. of the tank is subjected to pressure.
(c) All rivet heads on inside of tank must be buttonhead, or similar (b) The manway cover for spec. DOT–111A60W5, or 111A100W5
shape, and of uniform size. The under surface of heads must be driven must be made of a suitable metal. The top, bottom and edge of
tight against the plate. All plates, castings and rivet heads on the manway cover must be acid resistant material covered as prescribed
inside of the tank must be caulked. All projecting edges of plates, in §179.201–3. Through-bolt holes must be lined with acid resistant
castings and rivet heads on the inside of the tank must be rounded material at least one-eighth inch in thickness. Cover made of metal
and free from fins and other irregular projections. Castings must be not affected by the lading need not be acid resistant material covered.
free from porosity. (c) The manway ring and cover for specifications DOT–103CW,
(d) All surfaces of attachments or fittings and their closures exposed 103DW, 103EW, 111360W7, or 11A100W6 must be made of the metal
to the lading must be covered with at least 1⁄8-inch acid resistant and have the same inspection procedures specified in AAR Specifica-
material. Attachments made of metal not affected by the lading need tions for Tank Cars, appendix M, M3.03 (IBR, see §171.7 of this sub-
not be covered with rubber or other acid resistant material. chapter).
(e) Hard rubber or polyvinyl chloride may be used for pressure
retaining parts of safety vents provided the material is resistant to the §179.201–8@Sampling device and thermometer well. (a) Sam-
corrosive or solvent action of the lading in the liquid or gas phase pling valve and thermometer well are not specification requirements.
and is suitable for the service temperatures. When used, they must be of approved design, made of metal not
601
C-III [M-1002] 546 10/2007

M-1002 APPENDIX X
§179.201–8—§179.220–7 April 2007
subject to rapid deterioration by lading, and must withstand a pressure 5PL

of 100 psig without leakage. Interior pipes of the sampling valve must t=
6SE
be equipped with excess flow valves of an approved design. Interior
pipe of thermometer well must be closed by an approved valve Where:
attached close to fitting where it passes through the tank and closed
E = 0.9 welded joint efficiency; except E = 1.0 for seamless heads;
by a screw plug. Other approved arrangements that permit testing
L = Main inside radius to which head is dished, measured on con-
thermometer well for leaks without complete removal of the closure
cave side in inches;
may be used.
P = Minimum required bursting pressure in psig;
(b) [Reserved]
S = Minimum tensile strength of plate material in p.s.i. as prescribed
§179.201–9@Gauging device. A gauging device of an approved in AAR Specifications for Tank Cars, appendix M, Table M1;
design must be applied to permit determining the liquid level of the t = Minimum thickness of plate in inches after forming
lading. The gauging device must be made of materials not subject (c) The wall thickness after forming of the cylindrical section and
to rapid deterioration by the lading. When the interior pipe of the heads of the outer shell must be not less than seven-sixteenths of
gauging device provides a means for passage of the lading from the an inch.
interior to the exterior of the tank, it must be equipped with an excess (d) See §179.220–9 for plate thickness requirements for inner con-
flow valve of an approved design. If the opening for passage of lading tainer when divided into compartments.
through the gauging device is not more than 0.060 inch diameter an
excess flow valve is not required. The gauging device must be pro- §179.220–7@Materials. (a) The plate material used to fabricate
vided with a protective housing. the inner container and nozzles must meet one of the following
specifications and with the indicated minimum tensile strength and
§179.201–10@Water capacity marking. (a) Water capacity of the elongation in the welded condition.
tank in pounds stamped plainly and permanently in letters and figures (b) Carbon steel plate: The maximum allowable carbon content
at least 3⁄8 inch high into the metal of the tank immediately below the must be 0.31 percent when the individual specification allows carbon
stamped marks specified in §179.200–24(a). This mark shall also be content greater than this amount. The plates may be clad with other
stenciled on the jacket immediately below the dome platform and approved materials.
directly behind or within 3 feet of the right or left side of the ladder,
or ladders, if there is a ladder on each side of the tank, in letters and Minimum elongation in 2
figures at least 11⁄2 inches high as follows: Specifications (p.s.i.) welded condition1 metal (longitudinal)
WATER CAPACITY
AAR TC 128, Gr. B 81,000 19
000000 Pounds
(b) [Reserved] ASTM A 5162, Gr. 70 70,000 20
1
§179.201–11@Insulation. (a) Insulation shall be of sufficient thick- 2
This specification is incorporated by reference (IBR, see §171.7 of this subchapter).
ness so that the thermal conductance at 60°F. is not more than 0.075
Btu. per hour, per square foot, per degree F. temperature differential. (c) Aluminum alloy plate: Aluminum alloy plate must be suitable
for welding and comply with one of the following specifications (IBR,
§§179.202–179.202-22@[Reserved] see §171.7 of this subchapter):
§179.220@General specifications applicable to nonpressure tank Minimum tensile Minimum elongation in
car tanks consisting of an inner container supported within an strength (p.s.i.) 2 inches (percent) weld
Specifications welded condition3 4 metal (longitudinal)
outer shell (class DOT–115).
ASTM B 209, Alloy 50521 25,000 18
§179.220–1@Tanks built under these specifications must meet ASTM B 209, Alloy 50832 38,000 16
the requirements of §§179.220 and §179.221.
ASTM B 209, Alloy 50861 35,000 14
§179.220–3@Type. (a) Tanks built under these specifications must ASTM B 209, Alloy 5154 1
30,000 18
consist of an inner container, a support system for the inner container, ASTM B 209, Alloy 5254 1
30,000 18
and an outer shell.
ASTM B 209, Alloy 54541 31,000 18
(b) The inner container must be a fusion welded tank of circular
cross section with formed heads designed convex outward and must ASTM B 209, Alloy 56521 25,000 18
1
have a manway on top of the tank as prescribed herein. When the For fabrication, the parent plate material may be 0, H112, or H32 temper, but design
inner container is divided into compartments, each compartment must calculations must be based on minimum tensile strength shown.
2
0 temper only.
be considered a separate container. 3
Weld filler metal 5556 must not be used.
(c) The outer shell must be a fusion welded tank with formed heads 4
designed convex outward.
(d) High alloy steel plate: High alloy steel plate must comply with
§179.220–4@Insulation. The annular space between the inner con- one of the following specifications (IBR, see §171.7 of this subchapter):
tainer and the outer shell must contain an approved insulation material.
§179.220–6@Thickness of plates. (a) The wall thickness, after Minimum tensile strength inches (percent) weld
Specifications (p.s.i.) welded condition1 metal (longitudinal)
forming of the inner container shell and 2:1 ellipsoidal heads must be
not less than specified in §179.221–1, or not less than that calculated ASTM A 240/A 240M (incor- 75,000 30
by the following formula: §171.7 of this subchapter),
Type 304
Pd
t= ASTM A 240/A 240M (incor- 70,000 30
2SE porated by reference; see
§171.7 of this subchapter),
Where: Type 304L
d =
Inside diameter in inches; ASTM A 240/A 240M (incor- 74,000 30
E =
0.9 welded joint efficiency; except E = 1.0 for seamless heads; porated by reference; see
§171.7 of this subchapter),
P =
Minimum required bursting pressure in psig; Type 316
S =
Minimum tensile strength of plate material in psi as prescribed
ASTM A 240/A 240M (incor- 70,000 30
in AAR Specifications for Tank Cars, appendix M, Table M1 porated by reference; see
(IBR, see §171.7 of this subchapter); §171.7 of this subchapter),
t = Minimum thickness of plate in inches after forming. Type 316L
1
(b) The wall thickness after forming of the inner container heads, if
flanged and dished, must be not less than specified in §179.221–1, or (e) Manganese-molybdenum steel plate: Manganese-molybde-
not less than that calculated by the following formula: num steel plate must be suitable for fusion welding and must comply
602
10/2007 C-III [M-1002] 547

APPENDIX X M-1002
April 2007 §179.220–7—§179.220–17
with the following specification (IBR, see 171.7 of this subchapter): (d) Manway covers must be cast, forged, or fabricated metal com-
plying with subsection §179.220–7(g) of this section.
Minimum elongation in 2 (e) A seal must be provided between the inner container manway
Specifications (p.s.i.) welded condition1 metal (longitudinal)
nozzle and the opening in the outer shell.
ASTM A 302, Gr. B 80,000 20 §179.220–14@Openings in the tanks. Openings in the inner con-
1
Maximum stresses to be used in calculations. tainer and the outer shell must be reinforced in compliance with AAR
Specifications for Tank Cars, appendix E (IBR, see §171.7 of this
(f) Plate materials used to fabricate the outer shell and heads must subchapter). In determining the required reinforcement area for open-
be those listed in paragraphs (b), (c), (d), or (e) of this section. The ings in the outer shell, t shall be one-fourth inch.
maximum allowable carbon content must be 0.31 percent when the
individual specification allows carbon content greater than this §179.220–15@Support system for inner container (a) The inner
amount. The plates may be clad with other approved materials. container must be supported within the outer shell by a support system
(g) All appurtenances on the inner container in contact with the of adequate strength and ductility at its operating temperature to
lading must be made of approved material compatible with the plate support the inner container when filled with liquid lading to any level.
material of the inner container. These appurtenances must not be The support system must be designed to support, without yielding,
subject to rapid deterioration by the lading, or must be coated or lined impact loads producing accelerations of the following magnitudes
with suitable corrosion resistant material. See AAR Specifications for and directions when the inner container is loaded so that the car is
Tank Cars, appendix M, M4.05 for approved material specifications at its rail load limit, and the car is equipped with a conventional AAR
for castings for fittings. Specification M–901 draft gear.
§179.220–8@Tank heads. (a) Tank heads of the inner container, Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7G

inner container compartments and outer shell must be of approved Transverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G
contour, and may be flanged and dished or ellipsoidal for pressure Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3G
on concave side. (b) The longitudinal acceleration may be reduced to 3G where a
(b) Flanged and dished heads must have main inside radius not cushioning device of approved design, which has been tested to
exceeding 10 feet and inside knuckle radius must be not less than demonstrate its ability to limit body forces of 400,000 pounds maximum
3
3 ⁄4 inches for steel and alloy steel tanks nor less than 5 inches for at a 10 miles per hour impact, is used between the coupler and the
aluminum alloy tanks. tank structure. The support system must be of approved design and
(c) Ellipsoidal heads must be an ellipsoid of revolution in which the the inner container must be thermally isolated from the outer shell to
major axis must equal the diameter of the shell and the minor axis the best practical extent. The inner container and outer shell must be
must be one-half the major axis. permanently bonded to each other electrically either by the support
§179.220–9@Compartment tanks. (a) The inner container may be system used,piping, or by a separate electrical connection of ap-
divided into compartments by inserting interior heads, or by fabricating proved design.
each compartment as a separate container and joining with a cylinder,
or by fabricating each compartment as a separate tank without a §179.220–16@Expansion capacity. Expansion capacity must be
joining cylinder. Each compartment must be capable of withstanding, provided in the shell of the inner container as prescribed in
without evidence of yielding or leakage, the required test pressure §179.221–1.
applied in each compartment separately, or in any combination of
compartments. §179.220–17@Gauging devices, top loading and unloading de-
(b) When the inner container is divided into compartments by fabri- vices, venting and air inlet devices. (a) When installed, each de-
cating each compartment as a separate container and joining with a vice must be of approved design which will prevent interchange with
cylinder, the cylinder must have a plate thickness not less than that any other fixture and must be tightly closed. Each unloading pipe
required for the inner container shell and must be applied to the must be securely anchored within the inner container. Each inner
outside surface of the straight flange portion of the container head. container or compartment thereof may be equipped with one separate
The cylinder must fit the straight flange tightly for a distance of at least air connection.
two times the plate thickness, or 1 inch, whichever is greater and (b) When the characteristics of the commodity for which the car is
must be joined to the straight flange by a full fillet weld. Distance from authorized require these devices to be equipped with valves or fittings
fillet weld seam to container head seam must be not less than 11⁄2 to permit the loading and unloading of the contents, these devices
inches or three times the plate thickness, whichever is greater. including valves, shall be provided with a protective housing except
when plug or ball-type valves with operating handles removed are
§179.220–10@Welding. (a) All joints must be fusion welded in com- used. Provision must be made for closing pipe connections of valves.
pliance with AAR Specifications for Tank Cars, appendix W (IBR, (c) Inner container may be equipped with a vacuum relief valve of
see §171.7 of this subchapter). Welding procedures, welders, and approved design. Protective housing is not required.
fabricators shall be approved. (d) When a gauging device is required in §179.221–1, an outage
(b) Radioscopy of the outer shell is not a specification requirement. scale visible through the manway opening must be provided. If
(c) Welding is not permitted on or to ductile iron or malleable iron loading devices are applied to permit tank loading with cover
fittings. closed, a telltale pipe may be provided. The telltale pipe must be
§179.220–11@Postweld heat treatment. (a) Postweld heat treat- capable of determining that required outage is provided. The pipe
ment of the inner container is not a specification requirement. must be equipped with 1⁄4-inch maximum, NPT control valve mounted
(b) Postweld heat treatment of the cylindrical portions of the outer outside tank and enclosed within a protective housing. Other ap-
shell to which the anchorage or draft sills are attached must comply proved devices may be used in place of an outage scale or a
with AAR Specifications for Tank Cars, appendix W (IBR, see §171.7 telltale pipe.
of this subchapter). (e) The bottom of the tank shell may be equipped with a sump or
(c) When cold formed heads are used on the outer shell they must siphon bowl, or both, welded or pressed into the shell. These sumps
be heat treated before welding to shell if postweld heat treatment is or siphon bowls, if applied, are not limited in size and must be made
not practicable due to assembly procedures. of cast, forged, or fabricated metal. Each sump or siphon bowl must
be of good welding quality in conjunction with the metal of the tank
§179.220–13@Inner container manway nozzle and cover. shell. When the sump or siphon bowl is pressed in the bottom of the
(a) Inner container manway nozzle must be of approved design tank shell, the wall thickness of the pressed section must not be less
with access opening at least 18 inches inside diameter, or at least than that specified for the shell. The section of a circular cross section
14 inches by 18 inches obround or oval. tank to which a sump or siphon bowl is attached need not comply with
(b) Manway covers must be of approved type. Design must provide the out-of-roundness requirement specified in appendix W, W14.06 of
a secure closure of the manway and must make it impossible to remove the AAR Specifications for Tank Cars. Any portion of a sump or siphon
the cover while the tank interior is under pressure. bowl not forming a part of a cylinder of revolution must have walls of
(c) All joints between manway covers and their seats must be made such thickness and must be so reinforced that the stresses in the
tight against leakage of vapor and liquid by use of suitable gaskets. walls caused by a given internal pressure are not greater than the
603
C-III [M-1002] 548 10/2007

M-1002 APPENDIX X
§179.220–17—§179.221 April 2007
circumferential stress which would exist under the same internal pres- groove. The nozzle must be of a thickness to insure that accidental
sure in the wall of a tank of circular cross section designed in accord- breakage will occur at or below the “V” groove or its equivalent.
ance with §§179.220–6(a) and 179.220–9. In no case shall the wall On cars without a continuous center sill, the breakage groove or its
thickness be less than that specified in §179.221–1. equivalent may not be more than 15 inches below the outer shell. On
(f) Protective housing, when required, must be of approved material cars with continuous center sills, the breakage groove or its equivalent
and must have cover and sidewalls not less than 0.119 inch in must be above the bottom of the center sill construction.
thickness. (4) The closure plug and seat must be readily accessible or remov-
able for repairs.
(5) The closure of the washout nozzle must be equipped with a
§179.220–18@Bottom outlets. (a) The inner container may be 3
⁄4-inch solid screw plug. Plug must be attached by at least a 1⁄4-
equipped with a bottom outlet of approved design and an opening
inch chain.
provided in the outer shell for its access. If applied, the bottom outlet
(6) Joints between closures and their seats may be gasketed with
must comply with the following requirements:
suitable material.
(1) The extreme projection of the bottom outlet equipment may not
be more than that allowed by appendix E of the AAR Specifications
for Tank Cars (IBR, see §171.7 of this subchapter). All bottom outlet §179.220–20@Reinforcements, when used, and appurtenances
reducers and closures and their attachments shall be secured to car not otherwise specified. All attachments to inner container and
by at least 3⁄8-inch chain, or its equivalent, except that bottom outlet outer shell must be applied by approved means.
closure plugs may be attached by 1⁄4-inch chain. When the bottom
outlet closure is of the combination cap and valve type, the pipe §179.220–22@Closure for openings. (a) All plugs must be solid,
connection to the valve shall be closed by a plug, or cap. The bottom with NPT threads, and must be of a length which will screw at least
outlet equipment should include only the valve, reducers and closures six threads inside the face of fitting or tank. Plugs, when inserted from
that are necessary for the attachment of unloading fixtures. The perma- the outside of the outer shell tank heads, must have the letter “S” at
nent attachment of supplementary exterior fittings shall be approved least three-eighths inch in size stamped with steel stamp or cast on
by the AAR Committee on Tank Cars. the outside surface to indicate the plug is solid.
(2) Each bottom outlet must be provided with a liquid tight closure (b) Openings in the outer shell used during construction for installa-
at its lower end. tion must be closed in an approved manner.
(3) The valve and its operating mechanism must be applied to the
outside bottom of the inner container. The valve operating mechanism §179.220–23@Test of tanks. (a) Each inner container or compart-
must be provided with a suitable locking arrangement to insure positive ment must be tested hydrostatically to the pressure specified in
closure during transportation. §179.221–1. The temperature of the pressurizing medium must not
(4) Valve outlet nozzle and valve body must be of cast, fabricated exceed 100°F. during the test. The container must hold the pre-
or forged metal. If welded to inner container, they must be of good scribed pressure for at least 10 minutes without leakage or evidence
weldable quality in conjunction with metal of tank. of distress. Safety relief devices must not be in place when the
(5) To provide for the attachment of unloading connections, the test is made.
bottom of the main portion of the outlet nozzle or valve body, or some (b) The inner container must be pressure tested before installation
fixed attachment thereto, must be provided with threaded cap closure within the outer shell. Items which, because of assembly sequence,
arrangement or bolted flange closure arrangement having minimum must be welded to inner container after its installation within outer
1-inch threaded pipe plug. shell must have their attachment welds thoroughly inspected by a
(6) If outlet nozzle and its closure extends below the bottom of nondestructive dye penetrant method or its equivalent.
the outer shell, a V-shaped breakage groove shall be cut (not cast) (c) Pressure testing of outer shell is not a specification requirement.
in the upper part of the outlet nozzle at a point immediately below
the lowest part of the valve closest to the tank. In no case may §179.220–24@Tests of pressure relief valves. Each pressure relief
the nozzle wall thickness at the root of the “V” be more than 1⁄4- valve must be tested by air or gas for compliance with §179.15 before
inch. The outlet nozzle or the valve body may be steam jacketed, being put into service.
in which case the breakage groove or its equivalent must be
below the steam chamber but above the bottom of the center sill §179.220–25@Stamping. To certify that the tank complies with all
construction. If the outlet nozzle is not a single piece or its exterior specification requirements, each outer shell must be plainly and per-
valves are applied, provision shall be made for the equivalent of manently stamped in letters and figures at least 3⁄8-inch high into the
the breakage groove. On cars without continuous center sills, the metal near the center of both outside heads as follows:
breakage groove or its equivalent may not be more than 15 inches
below the outer shell. On cars with continuous center sills, the Examples of required stamping
breakage groove or its equivalent must be above the bottom of Specifications DOT–115A60W6
the center sill construction.
Inner container:
(7) The valve body must be of a thickness which will prevent distortion Material ASTM A240–316L
of the valve seat or valve by any change in contour of the shell resulting
Shell thickness Shell 0.167 in.
from expansion of lading, or other causes, and which will insure that
accidental breakage of the outlet nozzle will occur at or below the “V” Head thickness Head 0.150 in.
groove, or its equivalent. Tank builder’s initials ABC
(8) The valve must have no wings or stem projection below the “V” Date of original test 00–0000
groove or its equivalent. The valve and seat must be readily accessible Outer shell:
or removable for repairs, including grinding. Material ASTM A285–C
(b) Inner container may be equipped with bottom washout of ap- Tank builder’s initials WYZ
proved design. If applied, bottom washout must comply with the follow-
Car assembler (if other than inner container or outer
ing requirements: shell builders) DEF
(1) The extreme projection of the bottom washout equipment may
not be more than that allowed by appendix E of the AAR Specifications
for Tank Cars. §179.220–26@Stenciling. (a) The outer shell, or the jacket if the
(2) Bottom washout must be of cast, forged or fabricated metals. outer shell is insulated, must be stenciled in compliance with AAR
If it is welded to the inner container, it must be of good weldable Specifications for Tank Cars, appendix C (IBR, see §171.7 of this
quality in conjunction with metal of tank. subchapter).
(3) If washout nozzle extends below the bottom of the outer shell, (b) Stenciling must be applied on both sides of the outer shell or
a V-shaped breakage groove shall be cut (not cast) in the upper part jacket near the center in letters and figures at least 11⁄2 inches high
of the nozzle at a point immediately below the lowest part of the inside to indicate the safe upper temperature limit, if applicable, for the inner
closure seat or plug. In no case may the nozzle wall thickness at the tank, insulation, and the support system.
root of the “V” be more than 1⁄4-inch. Where the nozzle is not a single
piece, provisions shall be made for the equivalent of the breakage §179.221@Individual specification requirements applicable to
604
10/2007 C-III [M-1002] 549

APPENDIX X M-1002
April 2007 §179.221—§179.300–9
tank car tanks consisting of an inner container supported within §179.221–1@Individual specification requirements. In addition to
an outer shell. §179.220, the individual specification requirements are as follows:
Bursting pressure Minimum plate Test pressure Reference

DOT specification Insulation (psig) thickness (inches) (psig) Bottom outlet Bottom washout (179.221–***)
115A60ALW Yes 240 3
⁄16 60 Optional Optional
115A60W1 Yes 240 1
⁄8 60 Optional Optional 1
115A60W6 Yes 240 1
⁄8 60 Optional Optional 1
Subpart E
SPECIFICATIONS FOR MULTI-UNIT TANK CAR TANKS
(Classes DOT–106A and 110AW)
§179.300@General specifications applicable to multi-unit tank car tanks must conform with the following specifications with the indicated
tanks designed to be removed from car structure for filling and minimum tensile strength and elongation in the welded condition.
emptying (Classes DOT–106A and 110AW). However, the maximum allowable carbon content for carbon steel
must not exceed 0.31 percent, although the individual ASTM specifica-
§179.300–1@Tanks built under these specifications shall meet tion may allow for a greater amount of carbon. The plates may be
the requirements of §179.300, §179.301 and when applicable, clad with other approved materials:
§179.302.
Minimum tensile Minimum elongation in 2
strength (p.s.i.) inches (percent) 1 weld
§179.300–3@Type and general requirements. (a) Tanks built un- Specifications welded condition 1 metal (longitudinal)
der this specification shall be cylindrical, circular in cross section, and
ASTM A 240/A 240M type 304 75,000 25
shall have heads of approved design. All openings shall be located in
ASTM A 240/A 240M type 304L 70,000 25
the heads.
(b) Each tank shall have a water capacity of at least 1500 pounds ASTM A 240/A 240M type 316 75,000 25
and not more than 2600 pounds. ASTM A 240/A 240M type 316L 70,000 25
(c) For tanks made in foreign countries, a chemical analysis of ASTM A 240/A 240M type 321 75,000 25
materials and all tests as specified shall be carried out within the limits ASTM A 285 Gr. A 45,000 29
of the United States under the supervision of a competent and impartial ASTM A 285 Gr. B 50,000 20
inspector. ASTM A 285 Gr. C 55,000 20
ASTM A 515/A 515M Gr. 65 65,000 20
§179.300–4@Insulation. (a) Tanks shall not be insulated. ASTM A 515/A 515M Gr. 70 70,000 20
(b) [Reserved]
ASTM A 516/A 516M Gr. 70 70,000 20
1
§179.300–6@Thickness of plates. (a) For class DOT–110A tanks, 2
These specifications are incorporated by reference (IBR, see §171.7 of this subchapter.)
the wall thickness after forming of the cylindrical portion of the tank
must not be less than that specified in §179.301 nor that calculated (b) [Reserved]
by the following formula: (c) All plates must have their heat number and the name or brand
of the manufacturer legibly stamped on them at the rolling mill.
Pd
t= §179.300–8@Tank heads. (a) Class DOT–110A tanks shall have
2SE
fusion-welded heads formed concave to pressure. Heads for fusion
Where: welding shall be an ellipsoid of revolution 2:1 ratio of major to minor
axis. They shall be one piece, hot formed in one heat so as to provide
d = inside diameter in inches;
a straight flange at least 11⁄2 inches long. The thickness shall not be
E = 1.0 welded joint efficiency;
less than that calculated by the following formula:
P = minimum required bursting pressure in psig;
S = minimum tensile strength of plate material in p.s.i. as prescribed Pd
t=
in §179.300–7; 2SE
t = minimum thickness of plate material in inches after forming.
where symbols are as defined in §179.300–6(a).
(b) For class DOT–106A tanks, the wall thickness of the cylindrical (b) Class DOT–106A tanks must have forged-welded heads,
portion of the tank shall not be less than that specified in §179.301 formed convex to pressure. Heads for forge welding must be tori-
and shall be such that at the tank test pressure the maximum fiber spherical with an inside radius not greater than the inside diameter
stress in the wall of the tank will not exceed 15,750 p.s.i. as calculated of the shell. They must be one piece, hot formed in one heat so as
by the following formula: to provide a straight flange at least 4 inches long. They must have
p(1.3D 2 + 0.4d 2) snug drive fit into the shell for forge welding. The wall thickness after
s= forming must be sufficient to meet the test requirements of §179.300–
D2 − d2 16 and to provide for adequate threading of openings.
Where: §179.300–9@Welding. (a) Longitudinal joints must be fusion
d = inside diameter in inches; welded. Head-to-shell joints must be forge welded on class DOT–
D = outside diameter in inches; 106A tanks and fusion welded on class DOT–110A tanks. Welding
p = tank test pressure in psig; procedures, welders and fabricators must be approved in accordance
s = wall stress in psi. with AAR Specifications for Tank Cars, appendix W (IBR, see §171.7
of this subchapter).
(c) If plates are clad with material having tensile strength at least (b) Fusion-welded joints must be in compliance with the require-
equal to the base plate, the cladding may be considered a part of ments of AAR Specifications for Tank Cars, appendix W, except that
the base plate when determining the thickness. If cladding material circumferential welds in tanks less than 36 inches inside diameter
does not have tensile strength at least equal to the base plate, the need not be radiotaped.
base plate alone shall meet the thickness requirements. (c) Forge-welded joints shall be thoroughly hammered or rolled to
insure sound welds. The flanges of the heads shall be forge lapwelded
§179.300–7@Materials. (a) Steel plate material used to fabricate to the shell and then crimped inwardly toward the center line at least
605
C-III [M-1002] 550 10/2007

M-1002 APPENDIX X
§179.300–9—§179.302 April 2007
one inch on the radius. Welding and crimping must be accomplished the AAR Manual of Standards and Recommended Practices, Section
in one heat. C—Part III, AAR Specifications for Tank Cars (IBR, see §171.7 of this
§179.300–10@Postweld heat treatment. After welding is complete, subchapter).
steel tanks and all attachments welded thereto, must be postweld (c) For pressure relief devices of the fusible plug type, a sample
heat treated as a unit in compliance with the requirements of AAR of the plug used shall function at the temperatures prescribed in
Specifications for Tank Cars, appendix W (IBR, see §171.7 of this §179.300–15.
subchapter). (d) The start-to-discharge and vapor-tight pressures shall not be
affected by any auxiliary closure or other combination.
§179.300–12@Protection of fittings. (a) Tanks shall be of such
design as will afford maximum protection to any fittings or attachment §179.300–18@Stamping. (a) To certify that the tank complies with
to the head including the housing referred to in §179.300–12(b). Tank all specification requirements, each tank shall be plainly and perma-
ends shall slope or curve inward toward the axis so that the diameter nently stamped in letters and figures 3⁄8 inch high into the metal of
at each end is at least 2 inches less than the maximum diameter. valve end chime as follows:
(b) Loading and unloading valves shall be protected by a detach- (1) DOT Specification number.
able protective housing of approved design which shall not project (2) Material and cladding material if any (immediately below the
beyond the end of the tank and shall be securely fastened to the tank specification number).
head. Pressure relief devices shall not be covered by the housing. (3) Owner’s or builder’s identifying symbol and serial number (im-
mediately below the material identification). The symbol shall be regis-
§179.300–13@Venting, loading and unloading valves. (a) Valves tered with the Bureau of Explosives, duplications are not authorized.
shall be of approved type, made of metal not subject to rapid deteriora- (4) Inspector’s official mark (immediately below the owner’s or
tion by lading, and shall withstand tank test pressure without leakage. builder’s symbol).
The valves shall be screwed directly into or attached by other ap- (5) Date of original tank test (month and year, such as 1-64 for
proved methods to one tank head. Provision shall be made for closing January 1964). This should be so placed that dates of subsequent
outlet connections of the valves. tests may easily be added thereto.
(b) Threads for openings shall be National Gas Taper Threads (6) Water capacity—0000 pounds.
(NGT) tapped to gage, clean cut, even and without checks. (b) A copy of the above stamping in letters and figures of the
§179.300–14@Attachments not otherwise specified. Siphon prescribed size stamped on a brass plate secured to one of the tank
pipes and their couplings on the inside of the tank head and lugs on heads is authorized.
the outside of the tank head for attaching the valves protective housing §179.300–19@Inspection. (a) Tank shall be inspected within the
must be fusion-welded in place prior to postweld heat treatment. All United States and Canada by a competent and impartial inspector
other fixtures and appurtenances, except as specifically provided for, acceptable to the Bureau of Explosives. For tanks made outside the
are prohibited. United States and Canada, the specified inspection shall be made
§179.300–15@Pressure relief devices. (a) Unless prohibited in within the United States.
part 173 of this subchapter, tanks shall be equipped with one or more (b) The inspector shall carefully inspect all plates from which tanks
relief devices of approved type, made of metal not subject to rapid are to be made and secure records certifying that plates comply with
deterioration by the lading and screwed directly into tank heads or the specification. Plates which do not comply with §179.300–7 shall
attached to tank heads by other approved methods. The total dis- be rejected.
charge capacity shall be sufficient to prevent building up pressure in (c) The inspector shall make such inspection as may be necessary
tank in excess of 82.5 percent of the tank test pressure. When relief to see that all the requirements of this specification, including mark-
devices of the fusible plug type are used, the required discharge ings, are fully complied with; shall see that the finished tanks are
capacity shall be available in each head. See AAR Specifications for properly stress relieved and tested.
Tank Cars, appendix A (IBR, see §171.7 of this subchapter), for the (d) The inspector shall stamp his official mark on each accepted
formula for calculating discharge capacity. tank as required in §179.300–18, and render the report required in
(b) Threads for openings shall be National Gas Taper Threads §179.300–20.
(NGT) tapped to gage, clean cut, even and without checks.
§179.300–20@Reports. (a) Before a tank is placed in service, the
(c) Pressure relief devices shall be set for start-to-discharge and
inspector shall furnish to the builder, tank owner, Bureau of Explosives
rupture discs shall burst at a pressure not exceeding that specified
and the Secretary, Mechanical Division, Association of American
in §179.301.
Railroads, a report in approved form certifying that the tank and its
(d) Fusible plugs shall function at a temperature not exceeding
equipment comply with all the requirements of this specification.
175°F. and shall be vapor-tight at a temperature of not less than 130°F.
(b) For builder’s Certificate of Construction, see §179.5(b), (c),
§179.300–16@Tests of tanks. (a) After postweld heat treatment, and (d).
tanks shall be subjected to hydrostatic expansion test in a water jacket,
or by other approved methods. No tank shall have been subjected §179.301@Individual specification requirements for multi-unit
previously to internal pressure within 100 pounds of the test pressure. tank car tanks. (a) In addition to §179.300 the individual specifica-
Each tank shall be tested to the pressure prescribed in §179.301. tion requirements are as follows:
Pressure shall be maintained for 30 seconds and sufficiently longer DOT
to insure complete expansion of tank. Pressure gage shall permit Specifications 106A500–X 106A800–X 110A500–W 110A600–W 110A800–W 110A1000–W
reading to accuracy of one percent. Expansion gage shall permit Minimum required (1) (1) 1250 1500 2000 2500
reading of total expansion to accuracy of one percent. Expansion bursting pres-
shall be recorded in cubic centimeters. sure, psig
13 11 11 3 15 19
(1) No leaks shall appear and permanent volumetric expansion Minimum thickness ⁄32 ⁄16 ⁄32 ⁄8 ⁄32 ⁄32
shell, inches
shall not exceed 10 percent of total volumetric expansion at test
pressure. Test pressure, 500 800 500 600 800 1000
psig(see
(2) [Reserved]. §179.300– 16)
(b) After all fittings have been installed, each tank shall be subjected
Safety relief de-
to interior air pressure test of at least 100 psig under conditions favor- vices, psig(see
able to detection of any leakage. No leaks shall appear. §179.300–15)
(c) Repairs of leaks detected in manufacture or in foregoing tests Start-to-discharge, 375 600 375 450 600 700
shall be made by the same process as employed in manufacture of or burst maxi-
tank. Caulking, soldering, or similar repairing is prohibited. mum, psig
Vapor-tight, mini- 300 480 300 360 480 650
§179.300–17@Tests of pressure relief devices. (a) Each valve mum psig
1
shall be tested by air or gas before being put into service. The valve None specified
shall open and be vapor-tight at the pressure prescribed in §179.301. (b) [Reserved]
(b) Rupture disks of non-reclosing pressure relief devices must be
tested and qualified as prescribed in appendix A, Paragraph 5, of §179.302@[Reserved]
606
10/2007 C-III [M-1002] 551

APPENDIX X M-1002
April 2007 §179.400—§179.400–8
Subpart F
SPECIFICATION FOR CRYOGENIC LIQUID TANK CAR TANKS AND SEAMLESS STEEL TANKS
(Classes DOT–113 and 107A)
§179.400@General specification applicable to cryogenic liquid to performing the NER test; and
tank car tanks. (2) Have a CHTR equal to or less than 75 percent of the SHTR
specified in §179.401–1 table for a DOT–113C120W tank car.
§179.400–1@General. A tank built to this specification must comply (d) Insulating materials must be approved.
with §§179.400 and 179.401. (e) If the insulation consists of a powder having a tendency to settle,
the entire top of the cylindrical portion of the inner tank must be
§179.400–3@Type. (a) A tank built to this specification must— insulated with a layer of glass fiber insulation at least one-inch nominal
(1) Consist of an inner tank of circular cross section supported thickness, or equivalent, suitably held in position and covering an
essentially concentric within an outer jacket of circular cross section, area extending 25 degrees to each side of the top center line of the
with the out of roundness of both the inner tank and outer jacket limited inner tank.
in accordance with Paragraph UG—80 in Section VIII of the ASME (f) The outer jacket must be provided with fittings to permit effective
Code (IBR, see §171.7 of this subchapter); evacuation of the annular space between the outer jacket and the
(2) Have the annular space evacuated after filling the annular space inner tank.
with an approved insulating material; (g) A device to measure the absolute pressure in the annular space
(3) Have the inner tank heads designed concave to pressure; and must be provided. The device must be portable with an easily accessi-
(4) Have the outer jacket heads designed convex to pressure. ble connection or permanently positioned where it is readily visible
(b) The tank must be equipped with piping systems for vapor vent- to the operator.
ing and transfer of lading, and with pressure relief devices, controls,
gages and valves, as prescribed herein. §179.400–5@Materials. (a) Stainless steel of ASTM A 240/A 240M
(IBR, see §171.7 of this subchapter), Type 304 or 304L must be
§179.400–4@Insulation system and performance standard. used for the inner tank and its appurtenances, as specified in AAR
(a) For the purposes of this specification— Specifications for Tank Cars, appendix M (IBR, see §171.7 of this
(1) Standard Heat Transfer Rate (SHTR), expressed in Btu/day/ subchapter), and must be—
lb of water capacity, means the rate of heat transfer used for determin- (1) In the annealed condition prior to fabrication, forming and fusion
ing the satisfactory performance of the insulation system of a cryogenic welding;
tank car tank in cryogenic liquid service (see §179.401–1 table). (2) Suitable for use at the temperature of the lading; and
(2) Test cryogenic liquid means the cryogenic liquid, which may (3) Compatible with the lading.
be different from the lading intended to be shipped in the tank, being (b) Any steel casting, steel forging, steel structural shape or carbon
used during the performance tests of the insulation system. steel plate used to fabricate the outer jacket or heads must be as
(3) Normal evaporation rate (NER), expressed in lbs. (of the cryo- specified in AAR Specifications for Tank Cars, appendix M.
genic liquid)/day, means the rate of evaporation, determined by test (c) Impact tests must be—
of a test cryogenic liquid in a tank maintained at a pressure of approxi- (1) Conducted in accordance with AAR Specifications for Tank
mately one atmosphere, absolute. This determination of the NER is Cars, appendix W, W9.01;
the NER test. (2) Performed on longitudinal specimens of the material;
(4) Stabilization period means the elapsed time after a tank car (3) Conducted at the tank design service temperature or colder;
tank is filled with the test cryogenic liquid until the NER has stabilized, and
or 24 hours has passed, whichever is greater. (4) Performed on test plate welds and materials used for inner
(5) Calculated heat transfer rate. The calculated heat transfer tanks and appurtenances and which will be subjected to cryogenic
rate (CHTR) is determined by the use of test data obtained during temperatures.
the NER test in the formula: (d) Impact test values must be equal to or greater than those speci-
fied in AAR Specifications for Tank Cars, appendix W. The report of
q = [N(⌬h)(90−t1)]/[V(8.32828) (ts−tf)] impact tests must include the test values and lateral expansion data.
Where:
§179.400–6@Bursting and buckling pressure.
q = CHTR, in Btu/day/lb., of water capacity;
(a) [Reserved]
N = NER, determined by NER test, in lbs./day;
(b) The outer jacket of the required evacuated insulation system must
⌬h = latent heat of vaporization of the test cryogenic liquid
be designed in accordance with §179.400–8(d) and in addition must
at the NER test pressure of approximately one atmo-
comply with the design loads specified in Section 6.2 of the AAR Specifi-
sphere, absolute, in Btu/lb.;
cations for Tank Cars (IBR, see §171.7 of this subchapter). The designs
90 = ambient temperature at 90°F.;
and calculations must provide for the loadings transferred to the outer
V = gross water volume at 60°F. of the inner tank, in gallons;
jacket through the support system.
t1 = equilibrium temperature of intended lading at maximum
shipping pressure, in °F.; §179.400–7@Tank heads. (a) Tank heads of the inner tank and
8.32828 = constant for converting gallons of water at 60°F. to lbs. outer jacket must be flanged and dished, or ellipsoidal.
of water at 60°F., in lbs./gallon; (b) Flanged and dished heads must have—
t s = average temperature of outer jacket, determined by (1) A main inside dish radius not greater than the outside diameter
averaging jacket temperatures at various locations on of the straight flange;
the jacket at regular intervals during the NER test in °F.; (2) An inside knuckle radius of not less than 6 percent of the outside
t f = equilibrium temperature of the test cryogenic liquid at diameter of the straight flange; and
the NER test pressure of approximately, one atmo- (3) An inside knuckle radius of at least three times the head
sphere, absolute, in °F. thickness.
(b) DOT–113A60W tank cars must— §179.400–8@Thickness of plates. (a) The minimum wall thick-
(1) Be filled with hydrogen, cryogenic liquid to the maximum permit- ness, after forming, of the inner shell and any 2:1 ellipsoidal head for
ted fill density specified in §173.319(d)(2) table of this subchapter the inner tank must be that specified in §179.401–1, or that calculated
prior to performing the NER test; and by the following formula, whichever is greater:
(2) Have a CHTR equal to or less than the SHTR specified in
§179.401–1 table for a DOT–113A60W tank car. t = Pd/2SE
(c) DOT–113C120W tank cars must— Where:
(1) Be filled with ethylene, cryogenic liquid to the maximum permit- t = minimum thickness of plate, after forming, in inches;
ted fill density specified in §173.319(d)(2) table of this subchapter P = minimum required bursting pressure, in psig;
prior to performing the NER test, or be filled with nitrogen, cryogenic d = inside diameter, in inches;
liquid to 90 percent of the volumetric capacity of the inner tank prior S = minimum tensile strength of the plate material, as prescribed
607
C-III [M-1002] 552 10/2007

M-1002 APPENDIX X
§179.400–8—§179.400–12 April 2007
in AAR Specifications for Tank Cars, appendix M, Table M1 having two webs attached to the outer jacket, the jacket plate between
(IBR, see §171.7 of this subchapter), in psi; the webs may be included up to the limit of twice the value of “W”,
E = 0.9, a factor representing the efficiency of welded joints, except as defined in paragraph (b) of this section. The outer flange of the
that for seamless heads, E = 1.0. closed section, if not a steel structural shape, is subject to the same
limitations with “W” based on the “R” and “t” values of the flange.
(b) The minimum wall thickness, after forming, of any 3:1 ellipsoidal
Where two separate members such as two angles, are located less
head for the inner tank must be that specified in §179.401–1, or that
than “2W” apart they may be treated as a single stiffening ring member.
calculated by the following formula, whichever is greater:
(The maximum length of plate which may be considered effective is
t = 1.83 Pd/2SE 4W.) The closed section between an external ring and the outer jacket
Where: must be provided with a drain opening.
(d) The stiffening ring must have a moment of inertia large enough
t =
minimum thickness of plate, after forming, in inches;
to support the critical collapsing pressure, as determined by either
P =
minimum required bursting pressure, in psig;
of the following formulas:
d =
inside diameter, in inches;
S =
minimum tensile strength of the plate material, as prescribed I = [0.035D 3LPc]/E, or
in AAR Specifications for Tank Cars, appendix M, table M1, I′ = [0.046D 3LPc]/E
in psi;
E = 0.9, a factor representing the efficiency of welded joints, except Where:
that for seamless heads, E = 1.0. I = required moment of inertia of stiffening ring about the centroi-
(c) The minimum wall thickness, after forming, of a flanged and dal axis parallel to the vessel axis, in inches to the fourth
dished head for the inner tank must be that specified in §179.401–1, power;
or that calculated by the following formula, whichever is greater: I′ = required moment of inertia of combined section of stiffening
ring and effective width of jacket plate about the centroidal
PL (3 + √(L/r)) axis parallel to the vessel axis, in inches to the fourth power;
t= D = outside diameter of the outer jacket, in inches;
8SE
L = one-half of the distance from the centerline of the stiffening
Where: ring to the next line of support on one side, plus one-half of
t = minimum thickness of plate, after forming, in inches; the distance from the centerline to the next line of support on
P = minimum required bursting pressure, in psig; the other side of stiffening ring. Both distances are measured
L = main inside radius of dished head, in inches; parallel to the axis of the vessel, in inches. (A line of support is:
r = inside knuckle radius, in inches; (1) A stiffening ring which meets the requirements of this
S = minimum tensile strength of plate material, as prescribed in paragraph, or
AAR Specifications for Tank Cars, appendix M, table M1, in psi; (2) A circumferential line of a head at one-third the depth of
E = 0.9, a factor representing the efficiency of welded joints, except the head from the tangent line);
that for seamless heads, E = 1.0. Pc = critical collapsing pressure (37.5 psi minimum), in psig;
E = modulus of elasticity of stiffening ring material, in psi.
(d) The minimum wall thickness, after forming, of the outer jacket
shell may not be less than 7⁄16 inch. The minimum wall thickness, after (e) Where loads are applied to the outer jacket or to stiffening rings
forming, of the outer jacket heads may not be less than 1⁄2 inch and from the system used to support the inner tank within the outer jacket,
they must be made from steel specified in §179.16(c). The annular additional stiffening rings, or an increased moment of inertia of the
space is to be evacuated, and the cylindrical portion of the outer stiffening rings designed for the external pressure, must be provided
jacket between heads, or between stiffening rings if used, must be to carry the support loads.
designed to withstand an external pressure of 37.5 psig (critical col-
lapsing pressure), as determined by the following formula: §179.400–10@Sump or siphon bowl. A sump or siphon bowl may
be in the bottom of the inner tank shell if—
Pc = [2.6E(t/D2.5]/[(L/D) − 0.45(t/D)0.5]
(a) It is formed directly into the inner tank shell, or is formed and
Where: welded to the inner tank shell and is of weldable quality metal that is
Pc = Critical collapsing pressure (37.5 psig minimum), in psig; compatible with the inner tank shell;
E = modulus of elasticity of jacket material, in psi; (b) The stress in any orientation under any condition does not ex-
t = minimum thickness of jacket material, after forming, in inches; ceed the circumferential stress in the inner tank shell; and
D = outside diameter of jacket, in inches; (c) The wall thickness is not less than that specified in §179.401–1.
L = distance between stiffening ring centers in inches. (The heads
may be considered as stiffening rings located 1⁄3 of the head §179.400–11@Welding. (a) Except for closure of openings and a
depth from the head tangent line.) maximum of two circumferential closing joints in the cylindrical portion
of the outer jacket, each joint of an inner tank and the outer jacket
§179.400–9@Stiffening rings. (a) If stiffening rings are used in de- must be a fusion double welded butt joint.
signing the cylindrical portion of the outer jacket for external pressure, (b) The closure for openings and the circumferential closing joints
they must be attached to the jacket by means of fillet welds. Outside in the cylindrical portion of the outer jacket, including head to shell
stiffening ring attachment welds must be continuous on each side of joints, may be a single welded butt joint using a backing strip on the
the ring. Inside stiffening ring attachment welds may be intermittent inside of the joint.
welds on each side of the ring with the total length of weld on each (c) Each joint must be welded in accordance with the requirements
side not less than one-third of the circumference of the tank. The of AAR Specifications for Tank Cars, appendix W (IBR, see §171.7
maximum space between welds may not exceed eight times the outer of this subchapter).
jacket wall thickness. (d) Each welding procedure, welder, and fabricator must be ap-
(b) A portion of the outer jacket may be included when calculating proved.
the moment of inertia of the ring. The effective width of jacket plate
on each side of the attachment of the stiffening ring is given by the §179.400–12@Postweld heat treatment. (a) Postweld heat treat-
following formula: ment of the inner tank is not required.
(b) The cylindrical portion of the outer jacket, with the exception
W = 0.78(Rt)0.5 of the circumferential closing seams, must be postweld heat treated
Where: as prescribed in AAR Specifications for Tank Cars, appendix W (IBR,
W = width of jacket effective on each side of the stiffening ring, in see §171.7 of this subchapter). Any item to be welded to this portion
inches; of the outer jacket must be attached before postweld heat treatment.
R = outside radius of the outer jacket, in inches; Welds securing the following need not be postweld heat treated when
t = plate thickness of the outer jacket, after forming, in inches. it is not practical due to final assembly procedures:
(1) the inner tank support system to the outer jacket,
(c) Where a stiffening ring is used that consists of a closed section (2) connections at piping penetrations,
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APPENDIX X M-1002
April 2007 §179.400–12—§179.400–20
(3) closures for access openings, and (3) Vapor phase blowdown line. A blowdown line must be pro-
(4) circumferential closing joints of head to shell joints. vided. It must be attached to the vapor phase line specified in para-
(c) When cold formed heads are used on the outer jacket they graph (a)(2) of this section, upstream of the shut-off valve in that
must be heat treated before welding to the jacket shell if postweld line. A by-pass line with a manually operated shut-off valve must be
heat treatment is not practical due to assembly procedures. provided to permit reduction of the inner tank pressure when the vapor
phase line is connected to a closed system. The discharge from this
§179.400–13@Support system for inner tank. (a) The inner tank line must be outside the housing and must be directed upward and
must be supported within the outer jacket by a support system of away from operating personnel.
approved design. The system and its areas of attachment to the (b) Any pressure building system provided for the purpose of pres-
outer jacket must have adequate strength and ductility at operating surizing the vapor space of the inner tank to facilitate unloading the
temperatures to support the inner tank when filled with the lading to liquid lading must be approved.
any level incident to transportation.
(b) The support system must be designed to support, without yield- §179.400–18@Test of inner tank. (a) After all items to be welded
ing, impact loads producing accelerations of the following magnitudes to the inner tank have been welded in place, the inner tank must be
and directions when the inner tank is fully loaded and the car is pressure tested at the test pressure prescribed in §179.401–1. The
equipped with a conventional draft gear: temperature of the pressurizing medium may not exceed 100°F. during
the test. The inner tank must hold the prescribed pressure for a period
Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7“g”
of not less than ten minutes without leakage or distortion. In a pneu-
Transverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3“g”
matic test, due regard for the protection of all personnel should be
Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3“g”
taken because of the potential hazard involved. After a hydrostatic
The longitudinal acceleration may be reduced to 3“g” where a cushion- test the container and piping must be emptied of all water and purged
ing device of approved design, which has been tested to demonstrate of all water vapor.
its ability to limit body forces to 400,000 pounds maximum at 10 miles (b) Caulking of welded joints to stop leaks developed during the
per hour, is used between the coupler and the tank structure. test is prohibited. Repairs to welded joints must be made as prescribed
(c) The inner tank and outer jacket must be permanently bonded in AAR Specifications for Tank Cars, appendix W (IBR, see §171.7 of
to each other electrically, by either the support system,piping, or a this subchapter).
separate electrical connection of approved design.
§179.400–19@Valves and gages. (a) Valves. Manually operated
§179.400–14@Cleaning of inner tank. The interior of the inner tank shut-off valves and control valves must be provided wherever needed
and all connecting lines must be thoroughly cleaned and dried prior for control of vapor phase pressure, vapor phase venting, liquid trans-
to use. Proper precautions must be taken to avoid contamination of fer and liquid flow rates. All valves must be made from approved
the system after cleaning. materials compatible with the lading and having satisfactory properties
at the lading temperature.
§179.400–15@Radioscopy. Each longitudinal and circumferential (1) Liquid control valves must be of extended stem design.
joint of the inner tank, and each longitudinal and circumferential double (2) Packing, if used, must be satisfactory for use in contact with
welded butt joint of the outer jacket, must be examined along its entire the lading and of approved materials that will effectively seal the valve
length in accordance with the requirements of AAR Specifications for stem without causing difficulty of operation.
Tank Cars, appendix W (IBR, see §171.7 of this subchapter). (3) Each control valve and shut-off valve must be readily operable.
These valves must be mounted so that their operation will not transmit
§179.400–16@Access to inner tank. (a) The inner tank must be excessive forces to the piping system.
provided with a means of access having a minimum inside diameter (b) Gages. Gages, except portable units, must be securely
of 16 inches. Reinforcement of the access opening must be made of mounted within suitable protective housings. A liquid level gage and
the same material used in the inner tank. The access closure must a vapor phase pressure gage must be provided as follows:
be of an approved material and design. (1) Liquid level gage.
(b) If a welded closure is used, it must be designed to allow it to (i) A gage of approved design to indicate the quantity of liquefied
be reopened by grinding or chipping and to be closed again by lading within the inner tank, mounted where it will be readily
rewelding, preferably without a need for new parts. A cutting torch visible to an operator during transfer operations or storage, or
may not be used. a portable gage with a readily accessible connection, or
(ii) A fixed length dip tube, with a manually operated shut-off valve
§179.400–17@Inner tank piping. (a) Product lines. The piping located as close as practicable to the outer jacket. The dip
system for vapor and liquid phase transfer and venting must be made tube must indicate the maximum liquid level for the allowable
for material compatible with the product and having satisfactory prop- filling density. The inner end of the dip tube must be located
erties at the lading temperature. The outlets of all vapor phase and on the longitudinal centerline of the inner tank and within four
liquid phase lines must be located so that accidental discharge from feet of the transverse centerline of the inner tank.
these lines will not impinge on any metal of the outer jacket, car (2) Vapor phase pressure gage. A vapor phase pressure gage
structures, trucks or safety appliances. Suitable provision must be of approved design, with a manually operated shut-off valve located
made to allow for thermal expansion and contraction. as close as practicable to the outer jacket. The gage must indicate
(1) Loading and unloading line. A liquid phase transfer line must the vapor pressure within the inner tank and must be mounted where
be provided and it must have a manually operated shut-off valve it will be readily visible to an operator. An additional fitting for use of
located as close as practicable to the outer jacket, plus a secondary a test gage must be provided.
closure that is liquid and gas tight. This secondary closure must permit
any trapped pressure to bleed off before the closure can be removed §179.400–20@Pressure relief devices. (a) The tank must be pro-
completely. A vapor trap must be incorporated in the line and located vided with pressure relief devices for the protection of the tank assem-
as close as practicable to the inner tank. On a DOT–113A60W tank bly and piping system. The discharge from these devices must be
car, any loading and unloading line must be vacuum jacketed between directed away from operating personnel, principal load bearing mem-
the outer jacket and the shut-off valve and the shut-off valve must bers of the outer jacket, car structure, trucks and safety appliances.
also be vacuum jacketed. Vent or weep holes in pressure relief devices are prohibited. All main
(2) Vapor phase line. A vapor phase line must connect to the inner pressure relief devices must discharge to the outside of the protective
tank and must be of sufficient size to permit the pressure relief devices housings in which they are located, except that this requirement does
specified in §179.400–20 and connected to this line to operate at their not apply to pressure relief valves installed to protect isolated sections
design capacity without excessive pressure build-up in the tank. The of lines between the final valve and end closure.
vapor phase line must have a manually operated shut-off valve located (b) Materials. Materials used in pressure relief devices must be
as close as practicable to the outer jacket, plus a secondary closure suitable for use at the temperature of the lading and otherwise compati-
that is liquid and gas tight. This secondary closure must permit any ble with the lading in both the liquid and vapor phases.
trapped pressure to bleed off before the closure can be removed (c) Inner tank. Pressure relief devices for the inner tank must be
completely. attached to vapor phase piping and mounted so as to remain at
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C-III [M-1002] 554 10/2007

M-1002 APPENDIX X
§179.400–20—§179.400–24 April 2007
ambient temperature prior to operation. The inner tank must be (5) Safety interlock. If a safety interlock is provided for the pur-
equipped with one or more pressure relief valves and one or more pose of allowing transfer of lading at a pressure higher than the pres-
safety vents (except as noted in paragraph (c)(3)(iv) of this section), sure control valve setting but less than the pressure relief valve setting,
and installed without an intervening shut-off valve (except as noted the design must be such that the safety interlock will not affect the
in paragraph (c)(3)(iii) of this section). Additional requirements are as discharge path of the pressure relief valve or safety vent at any time.
follows: The safety interlock must automatically provide an unrestricted dis-
(1) Safety vent. The safety vent shall function at the pressure spec- charge path for the pressure control device at all times when the tank
ified in §179.401–1. The safety vent must be flow rated in accordance car is in transport service.
with the applicable provisions of AAR Specifications for Tank Cars, (d) Outer jacket. The outer jacket must be provided with a suitable
appendix A (IBR, see §171.7 of this subchapter), and provide sufficient system to prevent buildup of annular space pressure in excess of 16
capacity to meet the requirements of AAR Specifications for Tank psig or the external pressure for which the inner tank was designed,
Cars, appendix A, A8.07(a). whichever is less. The total relief area provided by the system must
(2) Pressure relief valve. The pressure relief valve must: be a minimum of 25 square inches, and means must be provided to
(i) be set to start-to-discharge at the pressure specified in prevent clogging of any system opening, as well as to ensure adequate
§179.401–1, and communication to all areas of the insulation space. If a safety vent is
(ii) meet the requirements of AAR Specifications for Tank Cars, a part of the system, it must be designed to prevent distortion of the
appendix A, A8.07(b). rupture disc when the annular space is evacuated.
(3) Installation of safety vent and pressure relief valve. (e) Piping system. Where a piping circuit can be isolated by clos-
ing a valve, means for pressure relief must be provided.
(i) Inlet piping.
(A) The opening through all piping and fittings between the
inner tank and its pressure relief devices must have a §179.400–21@Test of pressure relief valves. Each valve must be
cross-sectional area at least equal to that of the pressure tested with air or gas for compliance with §179.401–1 before being
relief device inlet, and the flow characteristics of this up- put into service.
stream system must be such that the pressure drop will
not adversely affect the relieving capacity or the proper §179.400–22@Protective housings. Each valve, gage, closure and
operation of the pressure relief device. pressure relief device, with the exception of secondary relief valves for
(B) When the required relief capacity is met by the use of the protection of isolated piping, must be enclosed within a protective
multiple pressure relief device placed on one connection, housing. The protective housing must be adequate to protect the
the inlet internal cross-sectional area of this connection enclosed components from direct solar radiation, mud, sand, adverse
must be sufficient to provide the required flow capacity for environmental exposure and mechanical damage incident to normal
the proper operation of the pressure relief device system. operation of the tank car. It must be designed to provide reasonable
(ii) Outlet piping. access to the enclosed components for operation, inspection and main-
(A) The opening through the discharge lines must have a cross- tenance and so that vapor concentrations cannot build up to a danger-
sectional area at least equal to that of the pressure relief ous level inside the housing in the event of valve leakage or pressure
device outlet and may not reduce the relieving capacity be- relief valve operation. All equipment within the protective housing must
low that required to properly protect the inner tank. be operable by personnel wearing heavy gloves and must incorporate
provisions for locks or seals. A protective housing and its cover must
(B) When the required relieving capacity is met by use of multi-
be constructed of metal not less than 0.119 inch thick.
ple pressure relief devices placed on a common discharge
manifold, the manifold outlet internal cross-sectional area
must be at least equal to the combined outlet areas of the §179.400–23@Operating instructions. All valves and gages must
pressure relief devices. be clearly identified with corrosion-resistant nameplates. A plate of
(iii) Duplicate pressure relief devices may be used when an ap- corrosion-resistant material bearing precautionary instructions for the
proved 3-way selector valve is installed to provide for relief safe operation of the equipment during storage and transfer operations
through either duplicate pressure relief device. The 3-way valve must be securely mounted so as to be readily visible to an operator.
must be included in the mounting prescribed by AAR Specifica- The instruction plate must be mounted in each housing containing
tions for Tank Cars, appendix A, A6.02(g), when conducting the operating equipment and controls for product handling. These instruc-
flow capacity test on the safety vent prescribed by AAR Specifi- tions must include a diagram of the tank and its piping system with
cations for Tank Cars, appendix A, A6.01. Flow capacity tests the various gages, control valves and pressure relief devices clearly
must be performed with the 3-way valve at both of the extreme identified and located.
positions as well as at the mid-position and the flow capacity
must be in accordance with AAR Specifications for Tank Cars, §179.400–24@Stamping. (a) A tank that complies with all specifi-
appendix A, A8.07(a). cation requirements must have the following information plainly and
(iv) An alternate pressure relief valve, set as required in §179.401– permanently stamped into the metal near the center of the head of
1, may be used in lieu of the safety vent, provided it meets the the outer jacket at the “B” end of the car, in letters and figures at least
3
flow capacity prescribed in AAR Specifications for Tank Cars, ⁄8-inch high, in the following order:
appendix A at a flow rating pressure of 110 percent of its start-
Example of
to-discharge pressure. Installation must— required stamping
(A) Prevent moisture accumulation at the seat by providing Specification DOT–113A60W
drainage away from the area,
Design service temperature Minus 423°F.
(B) Permit periodic drainage of the vent piping, and
Inner tank Inner Tank
(C) Prevent accumulation of foreign material in the vent system.
Material ASTM A240–304
(4) Evaporation control. The routine release of vaporized lading
may be controlled with a pressure controlling and mixing device, Shell thickness Shell 3⁄16 inch
except that a pressure controlling and mixing device is required on Head thickness Head 3⁄16 inch
each DOT–113A60W car. Any pressure controlling and mixing device Inside diameter ID 107 inch
must— Inner tank builder’s initials ABC
(i) Be set to start-to-discharge at a pressure not greater than that Date of original test (month and year) and initials of person 00–0000GHK
specified in §179.401–1; conducting original test
(ii) Have sufficient capacity to limit the pressure within the inner Water capacity 00000 lbs
tank to that pressure specified in §179.401–1, when the dis- Outer jacket Outer jacket
charge is equal to twice the normal venting rate during transpor-
Material ASTM A515–70
tation, with normal vacuum and the outer shell at 130°F; and
(iii) Prevent the discharge of a gas mixture exceeding 50% of the Outer jacket builder’s initials DEF
lower flammability limit to the atmosphere under normal condi- Car assembler’s initials (if other than inner tank or outer jacket
builder) XYZ
tions of storage or transportation.
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10/2007 C-III [M-1002] 555

APPENDIX X M-1002
April 2007 §179.400–24—§179.500–5
(b) Any stamping on the shell or heads of the inner tank is pro- Forged tanks shall be machined inside and outside before ends are
hibited. necked-down and, after necking-down, the ends shall be machined
(c) In lieu of the stamping required by paragraph (a) of this section, to size on the ends and outside diameter. Machining not neccessary
the specified markings may be incorporated on a data plate of corro- on inside or outside of seamless steel tubing, but required on ends
sion-resistant metal, fillet welded in place on the head of the outer after necking-down.
jacket at the “B” end of the car. (b) For tanks made in foreign countries, chemical analysis of mate-
rial and all tests as specified must be carried out within the limits of
§179.400–25@Stenciling. Each tank car must be stenciled in com- the United States under supervision of a competent and disinterested
pliance with the provisions of the AAR Specifications for Tank Cars, inspector; in addition to which, provisions in §179.500–18(b) and (c)
appendix C (IBR, see §171.7 of this subchapter). The stenciling must shall be carried out at the point of manufacture by a recognized
also include the following: inspection bureau with principal office in the United States.
(a) The date on which the rupture disc was last replaced and the (c) The terms “marked end” and “marked test pressure” used
initials of the person making the replacement, on the outer jacket in throughout this specification are defined as follows:
letters and figures at least 11⁄2 inches high. (1) “Marked end” is that end of the tank on which marks prescribed
(b) The design service temperature and maximum lading weight, in §179.500–17 are stamped.
in letters and figures at least 11⁄2 inches high adjacent to the hazardous (2) “Marked test pressure” is that pressure in psig which is indicated
material stencil. by the figures substituted for the * * * * in the marking DOT–107A * *
(c) The water capacity, in pounds net at 60°F., with the tank at its * * stamped on the marked end of tank.
coldest operating temperature, after deduction for the volume above (d) The gas pressure at 130°F. in the tank shall not exceed 7⁄10 of
the inlet to the pressure relief device or pressure control valve, struc- the marked test pressure of the tank.
tural members, baffles,piping, and other appurtenances inside the
tank, in letters and figures at least 11⁄2 inches high.
(d) Both sides of the tank car, in letters at least 11⁄2 inches high, §179.500–4@Thickness of wall. (a) Minimum thickness of wall of
with the statement “Do Not Hump or Cut Off While in Motion.” each finished tank shall be such that at a pressure equal to 7⁄10 of the
(e) The outer jacket, below the tank classification stencil, in letters marked test pressure of the tank, the calculated fiber stress in psi at
at least 11⁄2 inches high, with the statement, “vacuum jacketed.” inner wall of tank multiplied by 3.0 will not exceed the tensile strength
of any specimen taken from the tank and tested as prescribed in
§179.401@Individual specification requirements applicable to in- §179.500–7(b). Minimum wall thickness shall be 1⁄4 inch.
ner tanks for cryogenic liquid tank car tanks. (b) Calculations to determine the maximum marked test pressure
permitted to be marked on the tank shall be made by the formula:
§179.401–1@Individual specification requirements. In addition to
§179.400, the individual specification requirements for the inner tank 10S (D 2 − d 2)
P=
and its appurtenances are as follows: 7 (D 2 + d 2)
DOT specification 113A60W 113C120W Where:

Design service temperature, °F. −423 . . . . . . −260.
P = Maximum marked test pressure permitted;
Material §179.400–5 §179.400–5.
S = U
Impact test (weld and plate material) §179.400–5(c) §179.400–5(c).
3.0
Impact test values §179.400–5(d) §179.400–5(d).
Standard heat transfer rate. (Btu per day per lb. of Where:
water capacity, max.) (see §179.400–4) 0.097 0.4121.
Bursting pressure, min. psig 240 300.
U = Tensile strength of that specimen which shows
the lower tensile strength of the two specimens
Minimum plate thickness shell, inches (see
§179.400–7(a)) 3
⁄16 3
⁄16.
taken from the tank and tested as prescribed
in §179.500–7(b).
Minimum head thickness, inches (see §179.400–
8(a), (b), and (c)) 3
⁄16 3
⁄16. 3 = Factor of safety.
2 2 2 2
Test pressure, psig(see §179.400–16). 60 120.
(D − d )/(D + d ) = The smaller value obtained for this factor by
the operations specified in §179.500–4(c).
Safety vent bursting pressure, max, psig 60 120.
Pressure relief valve start-to-discharge pressure, (c) Measure at one end, in a plane perpendicular to the longitudinal
psi (⫾ 3 psig) 30 75. axis of the tank and at least 18 inches from that end before neck-
Pressure relief valve vapor tight pressure, min. ing-down:
psig 24 60.
d = Maximum inside diameter (inches) for the location under con-
Pressure relief valve flow rating pressure, max.
psig 40 85. sideration; to be determined by direct measurement to an accu-
racy of 0.05 inch.
Alternate pressure relief valve start-to-discharge
pressure, psig(⫾ 3 psig). 90. t = Minimum thickness of wall for the location under consideration;
Alternate pressure relief valve vapor tight
to be determined by direct measurement to an accuracy of
pressure, min. psig 72. 0.001 inch.
Alternate pressure relief valve flow rating Take D = d + 2t.
pressure, max. psig 100. Calculate the value of (D 2 − d 2)/(D 2 + d 2)
Pressure control valve. Start-to-vent, max. psig
(see §179.400–20(c)(4)). 17 Not required. (1) Make similar measurements and calculation for a corresponding
Relief device discharge restrictions §179.400–20 §179.400–20. location at the other end of the tank.
Transfer line insulation §179.400–17 Not required. (2) Use the smaller result obtained, from the foregoing, in making
calculations prescribed in paragraph (b) of this section.
§179.500@Specification DOT–107A * * * * seamless steel tank §179.500–5@Material. (a) Tanks shall be made from open-hearth
car tanks. or electric steel of uniform quality. Material must be free from seams,
cracks, laminations, or other defects injurious to finished tank. If not
§179.500–1@Tanks built under these specifications shall meet free from such defects, the surface may be machined or ground to
the requirements of §179.500. eliminate these defects. Forgings and seamless tubing for bodies of
tanks shall be stamped with heat numbers.
§179.500–3@Type and general requirements. (a) Tanks built un- (b) Steel (see Note 1) must conform to the following requirements
der this specification shall be hollow forged or drawn in one piece. as to chemical composition:
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C-III [M-1002] 556 10/2007

M-1002 APPENDIX X
§179.500–5—§179.500–15 April 2007
§179.500–8@Openings in tanks. (a) Each end shall be closed by

Class I Class II Class III
Designation (percent) (percent) (percent)
a cover made of forged steel. Covers shall be secured to ends of
tank by through bolts or studs not entering interior of tank. Covers
Carbon, maximum 0.50 0.50 0.53
shall be of a thickness sufficient to meet test requirements of §179.500–
Manganese, maximum 1.65 1.65 1.85 12 and to compensate for the openings closed by attachments pre-
Phosphorus, maximum .05 .05 .05 scribed herein.
Sulphur, maximum .06 .05 .05 (1) It is also provided that each end may be closed by internal
threading to accommodate an approved fitting. The internal threads
Silicon, maximum .35 .30 .37
as well as the threads on fittings for these openings shall be clean
Molybdenum, maximum .25 .30
cut, even, without checks, and tapped to gauge. Taper threads are
Chromium, maximum .30 .30 required and shall be of a length not less than as specified for American
Sum of manganese and carbon not over 2.10 2.10 Standard taper pipe threads. External threading of an approved type
Note 1: Alternate steel containing other alloying elements may be used if approved.
shall be permissible on the internal threaded ends.
(b) Joints between covers and ends and between cover and attach-
(1) For instructions as to the obtaining and checking of chemical ments shall be of approved form and made tight against vapor or
analysis, see §179.500–18(b)(3). liquid leakage by means of a confined gasket of suitable material.
(2) [Reserved]
§179.500–10@Protective housing. (a) Safety devices, and load-
§179.500–6@Heat treatment. (a) Each necked-down tank shall be ing and unloading valves on tanks shall be protected from accidental
uniformly heat treated. Heat treatment shall consist of annealing or damage by approved metal housing, arranged so it may be readily
normalizing and tempering for Class I, Class II and Class III steel or oil opened to permit inspection and adjustment of pressure relief devices
quenching and tempering for Class III steel. Tempering temperatures and valves, and securely locked in closed position. Housing shall be
shall not be less than 1000°F. Heat treatment of alternate steels shall provided with opening having an opening equal to twice the total
be approved. All scale shall be removed from outside of tank to an discharge area of pressure relief device enclosed.
extent sufficient to allow proper inspection. (b) [Reserved]
(b) To check uniformity of heat treatment, Brinnel hardness tests
shall be made at 18 inch intervals on the entire longitudinal axis. The §179.500–11@Loading and unloading valves. (a) Loading and
hardness shall not vary more than 35 points in the length of the tank. unloading valve or valves shall be mounted on the cover or threaded
No hardness tests need be taken within 12 inches from point of head into the marked end of tank. These valves shall be of approved type,
to shell tangency. made of metal not subject to rapid deterioration by lading or in service,
(c) A magnetic particle inspection shall be performed after heat and shall withstand without leakage a pressure equal to the marked
treatment on all tanks subjected to a quench and temper treatment test pressure of tank. Provision shall be made for closing service outlet
to detect the presence of quenching cracks. Cracks shall be removed of valves.
to sound metal by grinding and the surface exposed shall be blended (b) [Reserved]
smoothly into the surrounding area. A wall thickness check shall then
be made of the affected area by ultrasonic equipment or other suitable §179.500–12@Pressure relief devices. (a) Tank shall be equipped
means acceptable to the inspector and if the remaining wall thickness with one or more pressure relief devices of approved type and dis-
is less than the minimum recorded thickness as determined by charge area, mounted on the cover or threaded into the non-marked
§179.500–4(b) it shall be used for making the calculation prescribed end of the tank. If fittings are mounted on a cover, they shall be of
in paragraph (b) of this section. the flanged type, made of metal not subject to rapid deterioration by
lading or in service. Total flow capacity shall be such that, with tank
§179.500–7@Physical tests. (a) Physical tests shall be made on filled with air at pressure equal to 70 percent of the marked test
two test specimens 0.505 inch in diameter within 2-inch gauge length, pressure of tank, flow capacity will be sufficient to reduce air pressure
taken 180 degrees apart, one from each ring section cut from each to 30 percent of the marked test pressure within 3 minutes after pres-
end of each forged or drawn tube before necking-down, or one from sure relief device opens.
each prolongation at each end of each necked-down tank. These test (b) Pressure relief devices shall open at pressure not exceeding
specimen ring sections or prolongations shall be heat treated, with the marked test pressure of tank and not less than 7⁄10 of marked test
the necked-down tank which they represent. The width of the test pressure. (For tolerance for safety relief valves, see §179.500–16(a).)
specimen ring section must be at least its wall thickness. Only when (c) Cars used for the transportation of flammable gases shall have
diameters and wall thickness will not permit removal of 0.505 by 2- the safety devices equipped with an approved ignition device.
inch tensile test bar, laid in the transverse direction, may test bar cut
§179.500–13@Fixtures. (a) Attachments, other than those
in the longitudinal direction be substituted. When the thickness will
mounted on tank covers or serving as threaded closures for the ends
not permit obtaining a 0.505 specimen, then the largest diameter
of the tank, are prohibited.
specimen obtainable in the longitudinal direction shall be used. Speci-
(b) [Reserved]
mens shall have bright surface and a reduced section. When 0.505
specimen is not used the gauge length shall be a ratio of 4 to 1 length §179.500–14@Test of tanks. (a) After heat-treatment, tanks shall
to diameter. be subjected to hydrostatic tests in a water jacket, or by other accurate
(b) Elastic limit as determined by extensometer, shall not exceed method, operated so as to obtain reliable data. No tank shall have
70 percent of tensile strength for class I steel or 85 percent of tensile been subjected previously to internal pressure greater than 90 percent
strength for class II and class III steel. Determination shall be made of the marked test pressure. Each tank shall be tested to a pressure
at cross head speed of not more than 0.125 inch per minute with an at least equal to the marked test pressure of the tank. Pressure shall be
extensometer reading to 0.0002 inch. The extensometer shall be read maintained for 30 seconds, and sufficiently longer to insure complete
at increments of stress not exceeding 5,000 psi. The stress at which expansion of tank. Pressure gauge shall permit reading to accuracy
the strain first exceeds of one percent. Expansion gauge shall permit reading of total expan-
stress (psi) sion to accuracy of one percent. Expansion shall be recorded in cubic
+ 0.005 (inches per inch) centimeters.
30,000,000 (psi)
(b) No leaks shall appear and permanent volumetric expansion
shall be recorded as the elastic limit. shall not exceed 10 percent of the total volumetric expansion at test
(1) Elongation shall be at least 18 percent and reduction of area pressure.
at least 35 percent.
§179.500–15@Handling of tanks failing in tests. (a) Tanks re-
Note 1: Upon approval, the ratio of elastic limit to ultimate strength may be
jected for failure in any of the tests prescribed may be reheat-treated,
raised to permit use of special alloy steels of definite composition that will give
equal or better physical properties than steels herein specified. and will be acceptable if subsequent to reheat-treatment they are
subjected to and pass all of the tests.
(2) [Reserved] (b) [Reserved]
612
10/2007 C-III [M-1002] 557

APPENDIX X M-1002
April 2007 §179.500–16—§179.500–18
§179.500–16@Tests of pressure relief devices. (a) Pressure relief Location at

Built by Company
valves shall be tested by air or gas before being put into service. Location at
Valve shall open at pressure not exceeding the marked test pressure Consigned to Company
of tank and shall be vapor-tight at 80 percent of the marked test Location at
Quantity
pressure. These limiting pressures shall not be affected by any auxil- Length (inches)
iary closure or other combination. Outside diameter (inches)
(b) For pressure relief devices of that incorporate a rupture disc, Marks stamped into tank as required in §179.500–17 are:
samples of discs used shall burst at a pressure not exceeding the DOT–107A****
Note 1: The marked test pressure substituted for the **** on each tank is shown on Record
marked test pressure of tank and not less than 7⁄10 of marked test of General Data on Tanks attached hereto.
pressure. Serial numbers to inclusive
Inspector’s mark
Owner’s mark
§179.500–17@Marking. (a) Each tank shall be plainly and perma- Test date
nently marked, thus certifying that tank complies with all requirements Water capacity (see Record of Hydrostatic Tests).
of this specification. These marks must be stamped into the metal of Tare weights (yes or no) (see Record of Hydrostatic Tests).
necked-down section of tank at marked end, in letters and figures at These tanks were made by process of
Steel used was identified as indicated by the attached list showing the serial number of
least 1⁄4 inch high, as follows: each tank, followed by the heat number.
(1) Spec. DOT–107A****, the **** to be replaced by figures indicat- Steel used was verified as to chemical analysis and record thereof is attached hereto.
ing marked test pressure of the tank. This pressure shall not exceed Heat numbers were stamped into metal. All material was inspected and each tank was
inspected both before and after closing in ends; all material accepted was found free from
the calculated maximum marked test pressure permitted, as deter- seams, cracks, laminations, and other defects which might prove injurious to strength of
mined by the formula in §179.500–4(b). tank. Processes of manufacture and heat-treatment of tanks were witnessed and found to
(2) Serial number immediately below the stamped mark specified be efficient and satisfactory.
in paragraph (a)(1) of this section. Before necking-down ends, each tank was measured at each location prescribed in
§179.500–4(c) and minimum wall thickness in inches at each location was recorded; maximum
(3) Inspector’s official mark immediately below the stamped mark inside diameter in inches at each location was recorded; value of D in inches at each location
specified in paragraph (a)(1) of this section. was calculated and recorded; maximum fiber stress in wall at location showing larger value for
(4) Name, mark (other than trademark), or initials of company or D2 + d 2
person for whose use tank is being made, which shall be recorded D2 − d 2
with the Bureau of Explosives.
(5) Date (such as 1–01, for January 2001) of tank test, so placed was calculated for 7⁄10 the marked test pressure and recorded. Calculations were made by
the formula:
that dates of subsequent tests may easily be added.
(D 2 − d 2)
(6) Date (such as 1–01, for January 2001) of latest test of the pres-
sure relief device or of the rupture disc, required only when tank is
冤
S = 0.7P
(D 2 + d 2)
冥
used for transportation of flammable gases. Hydrostatic tests, tensile tests of material, and other tests as prescribed in this specification,
(b) [Reserved] were made in the presence of the inspector, and all material and tanks accepted were
found to be in compliance with the requirements of this specification. Records thereof are
attached hereto.
§179.500–18@Inspection and reports. (a) Before a tank car is I hereby certify that all of these tanks proved satisfactory in every way and comply with
placed in service, the party assembling the completed car shall furnish the requirements of Department of Transportation Specification No. 107A****.
to car owner, Bureau of Explosives, and the Secretary, Mechanical (Signed)
Division, Association of American Railroads, a report in proper form (Inspector)
(Place)
certifying that tanks and their equipment comply with all the require- (Date)
ments of this specification and including information as to serial num-
bers, dates of tests, and ownership marks on tanks mounted on car RECORD OF CHEMICAL ANALYSIS OF STEEL FOR TANKS
Numbered to inclusive
structure. Size inches outside diameter by inches long
(b) Purchaser of tanks shall provide for inspection by a competent Built by Company
inspector as follows: For Company
(1) Inspector shall carefully inspect all material and reject that not
Tanks Chemical analysis
complying with §179.500–5. repre-
(2) Inspector shall stamp his official mark on each forging or seam- sented
less tube accepted by him for use in making tanks, and shall verify Heat (serial
No. Nos.) C Mn P S Si Ni Cr Mo
proper application of heat number to such material by occasional
inspections at steel manufacturer’s plant.
(3) Inspector shall obtain certified chemical analysis of each heat
These analyses were made by
of material. (Signed)
(4) Inspector shall make inspection of inside surface of tanks before
(Place)
necking-down, to insure that no seams, cracks, laminations, or other (Date)
defects exist.
(5) Inspector shall fully verify compliance with specification, verify RECORD OF CHEMICAL ANALYSIS OF STEEL FOR TANKS
Numbered to inclusive
heat treatment of tank as proper; obtain samples for all tests and check Size inches outside diameter by inches long
chemical analyses; witness all tests; and report minimum thickness of Built by Company
tank wall, maximum inside diameter, and calculated value of D, for For Company
each end of each tank as prescribed in §179.500–4(c).
Tanks
(6) Inspector shall stamp his official mark on each accepted tank repre- Elon-
immediately below serial number, and make certified report (see para- sented gation
graph (c) of this section) to builder, to company or person for whose by test Elastic Tensile (percent Reduction
(Serial limit strength in 2 of area
use tanks are being made, to builder of car structure on which tanks Heat No. Nos.) (psi) (psi) inches) (percent)
are to be mounted, to the Bureau of Explosives, and to the Secretary,
Mechanical Division, Association of American Railroads.
(c) Inspector’s report required herein shall be in the following form:
(Signed)
(Place)
(Date) (Place)
(Date)
STEEL TANKS
It is hereby certified that drawings were submitted for these tanks under AAR Application RECORD OF HYDROSTATIC TESTS ON TANKS
for Approval and approved by the AAR Numbered to inclusive
Committee on Tank Cars under date of Size inches outside by inches long
Built for Company Built by Company
613
C-III [M-1002] 558 10/2007

M-1002 APPENDIX X
§179.500–18—Appendix B to Part 179 April 2007
For Company
Minimum weight of
Percent attached ram cars in kg Minimum velocity of
ratio of (pounds) impact in km/hour (mph) Restrictions
Perma- perma-
119,295 (263,000) . . . . . 29 (18) . . . . . . . . . . . One ram car only.
Total ment ment
expan- expan- expan- 155,582 (343,000) . . . . . 25.5 (16) . . . . . . . . . . One ram car or one car plus
Actual sion sion sion Capacity one rigidly attached car.
test (cubic (cubic to total Tare in pounds
Serial Nos. pressure centi- centi- expan- weight of water 311,164 (686,000) . . . . . 22.5 (14) . . . . . . . . . . One ram car plus one or more
of tanks (psig) meters) meters) sion 1 (pounds) 2 at 60°F. rigidly attached cars.
4. A test is successful if there is no visible leak from the standing

1
If tests are made by method involving measurement of amount of liquid forced into tank
tank car for at least one hour after impact.
by test pressure, then the basic data on which calculations are made, such as pump factors,
temperature of liquid, coefficient of compressibility of liquid, etc., must also be given.
2
Appendix B to Part 179—Procedures for Simulated Pool and
Do not include protective housing, but state whether with or without valves. Torch-Fire Testing
(Signed)
(Place) 1. This test procedure is designed to measure the thermal effects
(Date) of new or untried thermal protection systems and to test for system
survivability when exposed to a 100-minute pool fire and a 30-minute
RECORD OF GENERAL DATA ON TANKS
Numbered to inclusive torch fire.
Built by Company 2. Simulated pool fire test.
For Company a. A pool-fire environment must be simulated in the following
manner:
Data obtained as prescribed in (1) The source of the simulated pool fire must be hydrocarbon fuel
(S) Calculated fiber stress in psi at 7⁄10 marked
§179.500–4(c) with a flame temperature of 871°C (1,600°F), plus-or-minus 37.8°C

Marked test pressure in psig stamped in tank
Minimum tensile strength of material in psi

Marked end of tank Other end of tank (100°F), throughout the duration of the test.
Larger value of the factor D2 + d2/D2 – d2
(2) A square bare plate with thermal properties equivalent to the

(D) Calculated value of D in inches =
(D) Calculated value of D in inches =
material of construction of the tank car must be used. The plate dimen-
sions must be not less than one foot by one foot by nominal 1.6 cm
(t) Minimum thickness of wall in
(t) Minimum thickness of wall in

(d) Maximum inside diameter in
(d) Maximum inside diameter in
(0.625 inch) thick. The bare plate must be instrumented with not less
than nine thermocouples to record the thermal response of the bare
plate. The thermocouples must be attached to the surface not exposed
to the simulated pool fire and must be divided into nine equal squares
with a thermocouple placed in the center of each square.
Serial No. of tank
test pressure
(3) The pool-fire simulator must be constructed in a manner that

results in total flame engulfment of the front surface of the bare plate.
inches
inches
inches
inches
d + 2t
d + 2t
recorded
The apex of the flame must be directed at the center of the plate.
(4) The bare plate holder must be constructed in such a manner
that the only heat transfer to the back side of the bare plate is by heat
conduction through the plate and not by other heat paths.
(5) Before the bare plate is exposed to the simulated pool fire, none
of the temperature recording devices may indicate a plate temperature
(Signed)
in excess of 37.8°C (100°F) nor less than 0°C (32°F).
(6) A minimum of two thermocouple devices must indicate 427°C
Appendix A to Part 179—Procedures for Tank-Head Puncture- (800°F) after 13 minutes, plus-or-minus one minute, of simulated pool-
Resistance Test fire exposure.
1. This test procedure is designed to verify the integrity of new or b. A thermal protection system must be tested in the simulated
untried tank-head puncture-resistance systems and to test for system pool-fire environment described in paragraph 2a of this appendix in
survivability after coupler-to-tank-head impacts at relative speeds of the following manner:
29 km/hour (18 mph). Tank-head puncture-resistance is a function of (1) The thermal protection system must cover one side of a bare
one or more of the following: Head thickness, jacket thickness, insula- plate as described in paragraph 2a(2) of this appendix.
tion thickness, and material of construction. (2) The non-protected side of the bare plate must be instrumented
2. Tank-head puncture-resistance test. A tank-head puncture-re- with not less than nine thermocouples placed as described in para-
sistance system must be tested under the following conditions: graph 2a(2) of this appendix to record the thermal response of the
a. The ram car used must weigh at least 119,295 kg (263,000 plate.
pounds), be equipped with a coupler, and duplicate the condition (3) Before exposure to the pool-fire simulation, none of the thermo-
of a conventional draft sill including the draft yoke and draft gear. couples on the thermal protection system configuration may indicate
The coupler must protrude from the end of the ram car so that it a plate temperature in excess of 37.8°C (100°F) nor less than 0°C
is the leading location of perpendicular contact with the impacted (32°F).
test car. (4) The entire surface of the thermal protection system must be
b. The impacted test car must be loaded with water at six percent exposed to the simulated pool fire.
outage with internal pressure of at least 6.9 Bar (100 psig) and coupled (5) A pool-fire simulation test must run for a minimum of 100 minutes.
to one or more “backup” cars which have a total weight of 217,724 kg The thermal protection system must retard the heat flow to the plate
(480,000 pounds) with hand brakes applied on the last “backup” car. so that none of the thermocouples on the non-protected side of the
c. At least two separate tests must be conducted with the coupler plate indicate a plate temperature in excess of 427°C (800°F).
on the vertical centerline of the ram car. One test must be conducted (6) A minimum of three consecutive successful simulation fire tests
with the coupler at a height of 53.3 cm (21 inches), plus-or-minus 2.5 must be performed for each thermal protection system.
cm (1 inch), above the top of the sill; the other test must be conducted 3. Simulated torch fire test.
with the coupler height at 79 cm (31 inches), plus-or-minus 2.5 cm a. A torch-fire environment must be simulated in the following
(1 inch), above the top of the sill. If the combined thickness of the tank manner:
head and any additional shielding material is less than the combined (1) The source of the simulated torch must be a hydrocarbon fuel
thickness on the vertical centerline of the car, a third test must be with a flame temperature of 1,204°C (2,200°F), plus-or-minus 37.8°C
conducted with the coupler positioned so as to strike the thinnest (100°F), throughout the duration of the test. Furthermore, torch veloci-
point of the tank head. ties must be 64.4 km/h ⫾ 16 km/h (40 mph ⫾ 10 mph) throughout
3. One of the following test conditions must be applied: the duration of the test.
614
10/2007 C-III [M-1002] 559

APPENDIX X M-1002
April 2007 Appendix B to Part 179
(2) A square bare plate with thermal properties equivalent to the the following manner:
material of construction of the tank car must be used. The plate dimen- (1) The thermal protection system must cover one side of the bare
sions must be at least four feet by four feet by nominal 1.6 cm (0.625 plate identical to that used to simulate a torch fire under paragraphs
inch) thick. The bare plate must be instrumented with not less than 3a(2) of this appendix.
nine thermocouples to record the thermal response of the plate. The (2) The back of the bare plate must be instrumented with not less
thermocouples must be attached to the surface not exposed to the than nine thermocouples placed as described in paragraph 3a(2) of
simulated torch and must be divided into nine equal squares with a this appendix to record the thermal response of the material.
thermocouple placed in the center of each square. (3) Before exposure to the simulated torch, none of the thermocou-
(3) The bare plate holder must be constructed in such a manner ples on the back side of the thermal protection system configuration
that the only heat transfer to the back side of the plate is by heat may indicate a plate temperature in excess of 37.8°C (100°F) nor less
conduction through the plate and not by other heat paths. The apex than 0°C (32°F).
of the flame must be directed at the center of the plate. (4) The entire outside surface of the thermal protection system must
(4) Before exposure to the simulated torch, none of the temperature be exposed to the simulated torch-fire environment.
recording devices may indicate a plate temperature in excess of (5) A torch-simulation test must be run for a minimum of 30 minutes.
37.8°C (100°F) or less than 0°C (32°F). The thermal protection system must retard the heat flow to the plate
(5) A minimum of two thermocouples must indicate 427°C (800°F) in so that none of the thermocouples on the backside of the bare plate
four minutes, plus-or-minus 30 seconds, of torch simulation exposure. indicate a plate temperature in excess of 427°C (800°F).
b. A thermal protection system must be tested in the simulated (6) A minimum of two consecutive successful torch-simulation tests
torch-fire environment described in paragraph 3a of this appendix in must be performed for each thermal protection system.
615
C-III [M-1002] 560 10/2007

M-1002 APPENDIX X
Research and Special Programs by testing in accordance with system application number. The
Administration procedures contained in § 179.105–4 previous list of thermal protection
AGENCY: Department Of (d) and (e). The Federal Railroad systems excepted from test
Transportation (DOT); Administration (FRA) has received verification was published in the
Research and Special Programs test data from certain Federal Register on January 31,
Administration manufacturers and applicators 1986 (51 FR 4063). The current list
supporting that the thermal of thermal protection systems is as
DOC TYPE: Notices NUMBER: Notice follows:
No. 93-12 protection systems, identified in the
following list, maintained back plate Carborundum Company, Niagara
FOR FURTHER INFORMATION CON-
temperatures below 426 degrees °C Falls, New York
TACT:
(800 degrees° F) in both the pool and Fiberfrax
Edward Pritchard or James Rader, torch fire simulation tests. In
Federal Railroad Administration, addition, for certain materials System Application 01 (6): Apply
Office of Safety Enforcement, identified in §179.105–7 (c)(2) and 1.651 cm (0.65 inches) minimum
Hazardous Materials Division, 400 (d)(2), tanks may be equipped with thickness Fiberfrax thermal
Seventh Street, SW., room 8326-J, an optional safety relief valve having protection (density ≥72.1 kg/m sup3
Washington, DC 20590-0001, a smaller discharge capacity (4.5 lbs/ft sup3)), then an eleven
Telephone (202) 366-9178. provided the tank is insulated and gauge steel jacket.
ADDRESSES: The Dockets Unit the thermal protection system System Application 02 (22): (<288
(DHM-30), Research and Special maintains back plate temperatures degrees °C) Apply 1.27 cm (0.5 inch)
Programs Administration, U.S. below 288 degrees° C following list minimum thickness Fiberfrax
Department of Transportation, by the notation “(<288 degrees °C).” thermal protection (density ≥72.1 kg/
maintains a list of thermal In applying any of these thermal m sup3 (4.5 lbs/ft sup3)), compressed
protection systems that no longer protection systems, an applicator no less than 0.635 cm (0.25 inch)
need test verification. The current must first prepare surface areas with froth-in-place rigid urethane
list of thermal protection systems neighboring the system by foam, then an eleven gauge steel
and test results of each system are sandblasting, or by any other jacket. The total thickness of the
available for public review in Room equivalent method, to remove all Fiberfrax thermal protection and the
8421 of the Nassif Building, 400 existing paint, primer, oil, grease, urethane foam combination must be
Seventh Street, SW., Washington, and loose material. For systems at least 5.08 cm (2.0 inches).
DC 20590-0001. Public Dockets may employing a thermal blanket, the System Application 03 (23): (<288
be reviewed between the hours of interior of the tank jacket and the degrees °C) Apply 2.54 cm (1.0 inch)
8:30 a.m. and 5 p.m., Monday exterior of the tank shell must have minimum thickness Fiberfrax
through Friday. a protective coating. For systems thermal protection (density ≥72.1 kg/
ACTION: Notice; announcement of employing coatings (primers, m sup3 (4.5 lbs/ft sup3)), compressed
current list of thermal protection subliming compounds, films, no less than 1.372 cm (0.54 inches)
systems that no longer need test topcoats, etc.), the applicator shall with froth-in-place rigid urethane
verification for use on certain DOT measure the thickness of each foam, then an eleven gauge steel
specification tank cars. coating when dry and cured, before jacket. The total thickness of the
proceeding to the next application Fiberfrax thermal protection and the
SUMMARY: This notice contains a process. urethane foam combination must be
current list of thermal protection For further information on the use at least 5.08 cm (2.0 inches).
systems that are capable of passing of these systems, persons may System Application 04 (24): (<288
pool and torch fire tests specified in contact the FRA’s Office of Safety degrees °C) Apply 1.27 cm (0.5 inch)
the Hazardous Materials Enforcement, Hazardous Materials minimum thickness Fiberfrax
Regulations (HMR). The intended Division, 400 Seventh Street SW., thermal protection (density ≥68.9 kg/
effect of this action is to make room 8326-J, Washington, DC m sup3 (4.3 lbs/ft sup3)), then apply
persons aware that these thermal 20590-0001. Telephone (202) 366- 10.16 cm (4.0 inches) minimum
protection systems are acceptable for 9178. thickness glass fiber insulation
use, without further test This list of thermal protection compressed to 8.89 cm (3.5 inches),
verification, on certain class DOT systems remains open for additional and then an eleven gauge steel
105, 111, 112 and 114 tank cars. entries. To add a system to the list, jacket.
SUPPLEMENTARY INFORMATION: persons may submit test data and System Application 05 (29): Apply
The HMR, at 49 CFR 179.105–4, technical specifications showing that 1.27 cm (0.50 inch) minimum
require that class DOT 105J, 111J, the system successfully passes the thickness Fiberfrax thermal
112J, 112T, 114J and 114T tanks be pool and torch fire tests specified in protection (density ≥72.1 kg/m sup3
equipped with thermal protection 49 CFR 179.105–4, or 179.105–7 (4.5 lbs/ft sup3)), then an eleven
systems. As installed on the tank (c)(2) and (d)(2) to the FRA’s Office of gauge steel jacket.
car, the thermal protection system Safety Enforcement. System Application 06: Persons
must prevent release of any of the may use this system provided the
Thermal Protection Systems tank car is constructed from at least
tank car’s contents (except release Excepted From Test Verification
through the safety relief valve) when 1.905 cm (0.75 inch) carbon steel
In the current list, systems plate. Apply 1.27 cm (0.50 inch)
subjected to a pool fire for 100 appearing in the 1986 list are
minutes and a torch fire for 30 minimum thickness Fiberfrax
identified by their old system thermal protection and the glass fiber
minutes. Each material used as application number shown in
thermal protection must be verified parentheses following the new
10/2007 C-III [M-1002] 561

APPENDIX X M-1002
insulation combination must be at a 2.54 cm (1.0 inch) hexagonal, inches) minimum thickness
least 8.89 cm (3.5 inches). twenty-two gauge, wire mesh to the polyurethane foam then an eleven
Courtaulds Aerospace, Incorpo- primed surface. Next, apply 0.457 cm gauge steel jacket, then apply 0.005
rated, (180 mils) Chartek 59 thermal cm (2 mils) minimum of primer
Des Plaines, Illinois protection, then 0.008 cm (3 mils) of (Military Standard MIL-P-52192B,
AMERCOAT 383 (Brea, California) Mobile 13-R-56, or equivalent) to the
Thermal Shield Coating to the cured surface. clean surface. When desired,
System Application 01 (4): Apply System Application 02 (18): (<288 applicators may place a 2.54 cm (1.0
0.002 cm (7/10-mil) primer (a 2:1 degrees °C) Apply 5.08 cm (2.0 inch) hexagonal 22 gauge wire mesh
ratio by volume of 513–003 base inches) minimum thickness to the primed surface. Next, apply
component and 9110×350 activator polyurethane foam then an eleven 0.46 cm (180 mils) minimum
component). Next, apply 0.597 cm gauge steel jacket, then apply 0.005 thickness of Chartek 59 thermal
(235 mils) of Thermal Shield Coating cm (2 mils) minimum of primer protection to the cured surface.
(a nominal 5:1 ratio by volume of (Military Standard MIL-P-52192B, System Application 07 (34): (<288
821×359 base component and Mobile 13-R-56, or equivalent) to the degrees °C) Apply 5.08 cm (2.0
9110×407 activator component) to clean surface. Next, apply 0.53 cm inches) minimum thickness glass
the primed surface, then 0.005 cm (2 (210 mils) minimum thickness of fiber insulation then an eleven
mils) of topcoat (a 2:1 ratio by Chartek 59 thermal protection to the gauge steel jacket, then apply 0.005
volume of 821×317 base component cured surface. cm (2 mils) minimum of a polyamide
and 9110×376 activator component). System Application 03 (19): (<288 epoxy primer (Military Standard
Fibrex, Incorporated, degrees °C) Apply 5.08 cm (2.0 MIL-P-52192B, Mobile 13-R-56, or
Aurora, Illinois inches) minimum thickness glass equivalent) to the clean surface.
fiber then an eleven gauge steel When desired, applicators may place
Tank Wrap Insulation
jacket, then apply 0.005 cm (2 mils) a 2.54 cm (1.0 inch) hexagonal 22
System Application 01 (8): Apply minimum of primer (Military gauge wire mesh to the primed
3.81 cm (1.5 inches) minimum Standard MIL-P-52192B, Mobile 13- surface. Next, apply 0.46 cm (180
thickness Tank Wrap Insulation R-56, or equivalent) to the clean mils) minimum thickness of Chartek
(density ≥96.1 kg/m3 (6 lbs/ft3)), surface. Next, apply 0.46 cm (180 59 thermal protection to the cured
compressed to 2.54 cm (1.0 inch), mils) minimum thickness of Chartek surface.
then an eleven gauge steel jacket. 59 thermal protection to the cured System Application 08: Apply
Tank Car Insulation surface. 0.008 cm (3 mils) of primary
System Application 01 (25): (<288 System Application 04 (21): (<288 (Military Standard MIL-P-5219B),
degrees °C) Apply 3.81 cm (1.5 degrees °C) Apply 5.08 cm (2.0 then apply a 2.54 cm (1.0 inch)
inches) minimum thickness Tank inches) minimum thickness hexagonal, twenty-two gauge, wire
Car Insulation (density ≥96.1 kg/m3 polyurethane foam then an eleven mesh to the primed surface. Next,
(6 lbs/ft3)), and 7.62 cm (3.0 inches) gauge steel jacket, then apply 0.005 apply 0.46 cm (180 mils) Chartek 59
minimum thickness glass fiber cm (2 mils) minimum of primer thermal protection, then apply 0.008
insulation compressed to 6.35 cm (Military Standard MIL-P-52192B, cm (3 mils) of AMERCOAT (Brea,
(2.5 inches), then an eleven gauge Mobile 13-R-56, or equivalent) to the California) to the Chartek 59
steel jacket. clean surface. Next, apply 0.46 cm thermal protection to the cured
(180 mils) minimum thickness of surface.
Holmes, Insulation Limited, Chartek 59 thermal protection to the
Ontario, Canada Thermal Ceramics, Augusta, Geor-
cured surface. gia
HILBLOK 1212 System Application 05 (30): (<288
degrees °C) Apply 0.008 cm (3 mils) Kaowool Tank Car Blanket
System Application 01 (7): Apply
2.54 cm (1.0 inch) minimum of primer (Military Standard MIL-P- System Application 01 (5): Apply
thickness of HILBLOK 1212 52192B) to the clean surface. The 2.54 cm (1.0 inch) minimum
(density ≥200.2 kg/m3 (12.5 lbs/ft3)), use of a primer is optional when thickness of Kaowool Tank Car
then an eleven gauge steel jacket. facilities complete the surface Blanket (density ≥32.7 kg/m3 (2.04
preparation and coating operations lbs/ft3)), then an eleven gauge steel
Rock Wool Manufacturing, within six hours and the atmosphere jacket.
Leeds, Alabama has a dew point above 3 degrees °C System Application 02 (10): Apply
Delta Board (5 degrees °F). When desired, 1.32 cm (0.52 inches) minimum
System Application 01 (1): Apply applicators may place a 2.54 cm (1.0 thickness of Kaowool Tank Car
2.54 cm (1.0 inch) minimum inch) hexagonal 22 gauge wire mesh Blanket (density ≥76.9 kg/m3 (4.8
thickness of Delta Board (density to the primed surface. Next apply lbs/ft3)), then an eleven gauge steel
≥192.2 kg/m3 (12 lbs/ft3)), then an 0.457 cm (180 mils) of Chartek 59 jacket.
eleven gauge steel jacket. thermal protection to the cured System Application 03 (32): (<288
surface, then apply 0.008 cm (3 mils) degrees °C) Apply 2.54 cm (1.0 inch)
Textron Specialty Materials, minimum thickness of Kaowool
of a AMERCOAT 383 topcoat (Brea,
Lowell, Massachusetts Tank Car Blanket (density ≥72.1 kg/
California) to the Chartek 59
Chartek 59 thermal protection to the cured m3 (4.5 lbs/ft3)), then apply 10.16 cm
System Application 01 (3): Apply surface. (4.0 inches) of glass fiber insulation
0.008 cm (3 mils) of primer (Military System Application 06 (31): (<288 compressed to 7.62 cm (3.0 inches),
Standard MIL-P-5219B), then apply degrees °C) Apply 5.08 cm (2.0 then an eleven gauge steel jacket.
C-III [M-1002] 562 10/2007

M-1002 APPENDIX X
System Application 04 (33): (<288 may be added to the above lag Primer 351-3 primer to the tank
degrees °C) Apply 1.321 cm (0.52 components. jacket. Next, apply 0.48 cm (188
inches) minimum thickness of System Application 02: Apply mils) minimum thickness of Thermo-
Kaowool Tank Car Blanket (density 0.020 cm (8 mils) of Wisconsin lag 330-3 Subliming Compound.
≥76.9 kg/m3 (4.8 lbs/ft3)), then apply Protective Coatings’ Plasite 7156 Next apply 0.013 cm (5 mils) of
10.16 cm (4.0 inches) of glass fiber (Green Bay, Wisconsin), then apply Thermo-lag Topcoat 350-3.
insulation compressed to 8.89 cm 0.419 cm (165 mils) of Thermo-lag Thermo-lag 330-3 Subliming
(3.5 inches), then an eleven gauge 330-1 Subliming Compound. Next, Material System
steel jacket. apply 0.013 cm (5 mils) of Thermo-
System Application 05 (35): (<288 lag Topcoat 350. System Application 01 (15): Apply
degrees °C) Apply 2.54 cm (1.0 inch) 5.08 cm (2.0 inches) minimum
Thermo-lag 330-3 Subliming thickness of polyurethane foam then
minimum thickness of Kaowool Material System
Tank Car Blanket (density ≥72.1 kg/ an eleven gauge steel jacket, then
m3 (4.5 lbs/ft3)), then apply 10.16 cm System Application 01 (12): Apply apply 0.010 cm (4 mils) minimum
(4.0 inches) of glass fiber insulation 5.08 cm (2.0 inches) minimum thickness of Thermo-lag Primer 351-
compressed to 7.62 cm (3.0 inches), thickness of glass fiber then an eleven 3 to the tank jacket, and then apply
then an eleven gauge steel jacket. gauge steel jacket, then apply 0.010 0.343 cm (135 mils) minimum
System Application 06 (36): (<288 cm (4 mils) minimum thickness of thickness of Thermo-lag 330-30
degrees °C) Apply 1.321 cm (0.52 Thermo-lag Primer 351-3 primer to Subliming Compound. Next apply
inches) minimum thickness of the tank jacket. Next, apply 0.32 cm 0.013 cm (5 mils) of Thermo-lag
Kaowool Tank Car Blanket (density (125 mils) minimum thickness of Topcoat 350-3.
≥76.9 kg/m3 (4.8 lbs/ft3)), then apply Thermo-lag 330-3 Subliming System Application 02 (27): Apply
10.16 cm (4.0 inches) of glass fiber Compound, and then apply 0.013 cm 5.08 cm (2.0 inches) minimum
insulation compressed to 8.89 cm (5 mils) of Thermo-lag Topcoat 350-3. thickness of glass fiber then an
(3.5 inches), and then an eleven System Application 02 (13): Apply eleven gauge steel jacket, then apply
gauge steel jacket. 5.08 cm (2.0 inches) minimum 0.010 cm (4 mils) minimum
System Application 07: Apply 2.54 thickness of polyurethane, then an thickness of Thermo-lag Primer 351-
cm (1.0 inch) minimum thickness of eleven gauge steel jacket, then apply 3 primer to the tank jacket, and then
Kaowool Tank Car Blanket (density 0.010 cm (4 mils) minimum apply 0.46 cm (180 mils) minimum
≥64.1 kg/m3 (4 lbs/ft3)), then an eleven thickness of Thermo-lag Primer 351- thickness of Thermo-lag 330-30
gauge steel jacket having an annular 3 primer to the tank jacket, and then Subliming Compound. Next apply
space of 1.016 cm (0.4 inches) between apply 0.32 cm (125 mils) minimum 0.013 cm (5 mils) of Thermo-lag
the thermal protection and the steel thickness of Thermo-lag 330-3 Topcoat 350-3.
jacket. Subliming Compound. Next apply System Application 03 (28): Apply
0.013 cm (5 mils) of Thermo-lag 2.54 cm (1.0 inch) minimum thickness
Cerawool Tank Car Blanket Topcoat 350-3. of polyurethane foam then an eleven
System Application 01 (9): Apply System Application 03 (14): Apply gauge steel jacket, then apply 0.010
1.524 cm (0.6 inch) minimum 5.08 cm (2.0 inches) minimum cm (4 mils) minimum thickness of
thickness of Cerawool Tank Car thickness of glass fiber then an Thermo-lag Primer 351-3 to the tank
Blanket (density ≥64.1 kg/m3 (4 lbs/ eleven gauge steel jacket, then apply jacket, and then apply 0.457 cm (180
ft3)), then an eleven gauge steel 0.010 cm (4 mils) minimum mils) minimum thickness of Thermo-
jacket having an annular space of thickness of Thermo-lag Primer 351- lag 330-30 Subliming Compound.
1.016 cm (0.4 inches) between the 3 primer to the exterior tank jacket, Next apply 0.013 cm (5 mils) of
thermal protection and the jacket. and then apply 0.34 cm (135 mils) Thermo-lag Topcoat 350-3.
System Application 02: Apply 2.54 minimum thickness of Thermo-lag Thermo-Lag 440 Subliming Material
cm (1.0 inch) minimum thickness of 330-3 Subliming Compound. Next System
Cerawool Tank Car Blanket (density apply 0.013 cm (5 mils) of Thermo-
≥54.9 kg/m3 (3.43 lbs/ft3)), and 5.08 lag Topcoat 350-3. System Application 01: Apply
cm (2.0 inches) minimum thickness System Application 04 (16): (<288 0.013 cm (5 mils) of THERMO-LAG
polyurethane foam, then an eleven degrees °C) Apply 5.08 cm (2.0 351-176 Primer to the tank surface,
gauge steel jacket. inches) minimum thickness of glass then apply 0.419 cm (165 mils) of
fiber then an eleven gauge steel THERMO-LAG 440 Subliming
Thermal Sciences, Incorporated, Material to the surface. Next, apply
St. Louis, Missouri jacket, then apply 0.010 cm (4 mils)
minimum film thickness of Thermo- 0.005 cm (2 mils) of THERMO-LAG
Thermo-lag 330-1 Subliming lag Primer 341-3 primer to the tank 350-31 Topcoat.
Material System jacket, and then apply 0.48 cm (188 United States Gypsum Company,
System Application 01 (2): Apply mils) minimum thickness of Thermo- Chicago, Illinois
0.005 cm (2 mils) of Thermo-lag lag 330-3 Subliming Compound. Next Thermafiber Tank Car Fire Proofing
Primer 351, 0.127 cm (5 mils) apply 0.013 cm (5 mils) of Thermo-lag
Thermo-lag 351-EX176 Primer, or System Application 01 (11): Apply
Topcoat 350-3.
0.02 cm (8 mils) of PLASITE 7156 2.54 cm (1.0 inch) minimum thickness
System Application 05 (17): (<288 of Thermafiber Tank Car Fire
Primer, then apply 0.419 cm (165
mils) of Thermo-lag 330-1 Subliming
degrees °C) Apply 5.08 cm (2.0 proofing (density ≥112.1 kg/m3 (7 lbs/
inches) minimum thickness of ft3)), then an eleven gauge steel
Compound. Next, apply 0.013 cm (5 polyurethane then an eleven gauge
mils) of Thermo-lag Topcoat 350. jacket.
steel jacket, then apply 0.010 cm (4
Thermo-lag 330-CA cure accelerator mils) minimum thickness of Thermo-
10/2007 C-III [M-1002] 563

APPENDIX X M-1002
System Application 02 (20): (<288

degrees °C) Apply 2.54 cm (1.0 inch)
minimum thickness of Thermafiber
Tank Car Fire proofing (density
>112.1 kg/m3 (7 lbs/ft3)), with a foil
scrim polyethylene facing, then
apply 10.16 cm (4.0 inches) of glass
fiber compressed to 7.62 cm (3.0
inches), and then an eleven gauge
steel jacket.
System Application 03 (26): (<288
>112.1 kg/m3 (7 lbs/ft3)), with a foil
scrim polyethylene facing, then
apply 2.54 cm (1.0 inch) minimum
thickness polyurethane facing
followed by 2.54 cm (1.0 inch)
minimum thickness polyurethane
foam, and then an eleven gauge steel
jacket.
System Application 04: (<288
≥112.1 kg/m3 (7 lbs/ft3)), then apply
8.89 cm (3.5 inches) glass fiber
insulation compressed to 7.62 cm
(3.0 inches) and then an eleven
gauge steel jacket.
Inswool HO
System Application 01: (<288
minimum thickness of INSWOOL
HP ceramic fiber blanket (density
<80.1 kg/m3 (5 lbs/ft3)), then an
eleven gauge steel jacket.
Issued in Washington, DC on May
10, 1993 under authority delegated
in 49 CFR part 106, appendix A.
Alan I. Roberts,
Associate Administrator for
Hazardous Materials Safety.
[FR Doc. 93-11383; Filed 5-12-93;
8:45 am]
BILLING CODE 4910-60-P
C-III [M-1002] 564 10/2007

M-1002 APPENDIX Y
APPENDIX Y
SELECTED AAR CIRCULAR LETTERS
CONTENTS

Fig. No. Letter and Subject Date Page

Fig. Y1 C-6370 thermal coating overspray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10-79 C-III–567
Fig. Y2 C-6494 pressure car bottom fittings protectiona/ . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21-80 C-III–568
Fig. Y3 D.V. 2007 Exhibit 2, bottom fittings protection—commodity groupsa/ . . . . . . . . . . . 5-28-82 C-III–570
Fig. Y4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A,
B, C, and D)a/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28-82 C-III–571
Fig. Y5 D.V. 2007 addendum—additional commodity requirements . . . . . . . . . . . . . . . . . . 9-1-90 C-III–588
Fig. Y6 C-6993 minimum retention time for various tank car documentsa/ . . . . . . . . . . . . . 7-10-84 C-III–589
Fig. Y7 CPC-1097 stub sill inspection program—new Form SS-3 (page 1 of 5) . . . . . . . . . 9-07-99 C-III–590
Fig. Y8 CPC-1114 requirements for SS-3 inspections of tank car stub sills (page 1 of 4) . . 5-10-01 C-III–595
Fig. Y9 CPC-1116 Shop practices for installation and maintenance of bottom outlet valves
(page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30-01 C-III–599
a/ This reference has been updated in this publication
10/2007 C-III [M-1002] 565

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 Specifica-
tions for Tank Cars, but are believed to be of long-term relevance. These are copied in this appen-
dix for reference.
C-III [M-1002] 566 10/2007

M-1002 APPENDIX Y
Fig. Y1 C-6370 thermal coating overspray
10/2007 C-III [M-1002] 567

APPENDIX Y M-1002
Fig. Y2 C-6494 pressure car bottom fittings protection
C-III [M-1002] 568 10/2007

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 9.0, 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 accordance
with Appendix E, paragraph 9.0, of the AAR Tank Car Specifications except that the Tank Car
Committee will be receptive to proposals of alternate protection schemes when submitted by
car owners.
3. Sumps on existing cars, not exceeding 5 inches in depth, are exempt from require-
ments of Appendix E, paragraph 9.0,. 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 9.0,
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. Y2 C-6494 pressure car bottom fittings protection (continued)
10/2007 C-III [M-1002] 569

APPENDIX Y M-1002
Exhibit 2
Mechanical Division Circular D.V. 2007
Bottom Fittings Protection Requirements—AAR Commodity Groups 1 through 9(1)

Group 1—EPA Categories X, A, B
Group 2—Flammable and thermally unstable(2)
Flammable and polymerizable(3)
Flammable and poison
Flammable and corrosive
Group 3—EPA Categories C, D
Group 4—Vacant
Group 5—Poison
Group 6—Flammable
Group 7—Corrosive
Group 8—Combustible
Group 9—ORM 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 unstable—A material which, when exposed to elevated temperatures, will spontaneously
decompose with evolution of heat and pressure.
(3)Polymerizable—A 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. Y3 D.V. 2007 Exhibit 2, bottom fittings protection—commodity groups
C-III [M-1002] 570 10/2007

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
having internal closures) that extend more than 2 5/8 inches below the tank
shell longitudinal bottom center line (inclusive of bolting).
3. Approved protection shall be provided for all internally closed washouts that ex-
tend 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 bot-
tom center 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 longitudi-
nal bottom center 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 chemical
properties of the material in order to have the required level of protection assigned.
Fig. Y4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D)
10/2007 C-III [M-1002] 571

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 6 C
purposes)
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 6 C
Acetone cyanohydrin 1 A products and/or chemicals not to
Acetone oil 6 C exceed five percent)
Acetonitrile 2 B Alcohol, n.o.s. (denatured alcohol solvent) 6 C
Acetyl Bromide 3 B Alcohol, n.o.s. (denaturing alcohol, nec) 6 C
(flammable)
Acetyl chloride 3 B
Alcohol, n.o.s. (denaturing alcohol, nec) 8 C
Acetyl iodide 7 B (combustible)
Acid butyl phosphate 7 C Alcohol, n.o.s. (isopropanol and methanol
Acid, glacial methacrylic (corrosive liquid, 6 C
7 C mixture)
n.o.s.) Alcohol, n.o.s. (methanol, contaminated,
Acid, liquid, n.o.s. (acids, inorganic, nec, 6 C
7 D value only for refining)
liquid) Alcohol distillates, synthetic (alcohol, n.o.s.) 6 C
Acid, liquid, n.o.s. (acid, nec, liquid, (flammable)
7 D
organic) Alcohol distillates, synthetic (alcohol, n.o.s.) 8 C
Acrylamide solution (combustible liquid, (combustible)
8 C
n.o.s.) Alcoholic beverage (flammable) 6 C
Acrylamide solution (flammable liquid, 6 C Alcoholic beverage (combustible) 8 C
n.o.s.)
Alcohols, fatty or cyclic, ethoxylated 8 C
Acrylic acid 7 C (alcohol, n.o.s.) (combustible)
Acrylonitrile 1 A Alcohols, fatty or ethoxylated (alcohol, 6 C
Active sec-amyl alcohol (alcohol, n.o.s.) 6 C n.o.s.) (flammable)
Additives, fuel oil, gasoline, or lubricating Aldol (combustible liquid, n.o.s.) 8 C
oil, containing less than 50% by weight 8 C Aldrin 1 A
of petroleum (combustible liquid, n.o.s.)
Alkaline battery fluid 7 C
Additives, fuel oil, gasoline, or lubricating
oil, containing less than 50% by weight 6 C Alkaline (corrosive) liquid, n.o.s. 7 D
of petroleum (flammable liquid, n.o.s.) Alkaline (corrosive) liquid, n.o.s. (fatty 7 C
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
8 C
liquid) (combustible) ammonium compounds)
Adhesive, n.o.s. (insecticide adhesives, Alkanesulfonic acid 7 C
6 C
liquid) (flammable) 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. Y4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–572 10/2007
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. Y4 D.V. 2007 Exhibit 2, Bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
10/2007 C-III–573
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-III–574 10/2007
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)
10/2007 C-III–575
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-III–576 10/2007
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
10/2007 C-III–577
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-III–578 10/2007
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.)
10/2007 C-III–579
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-III–580 10/2007
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
10/2007 C-III–581
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-III–582 10/2007
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)
10/2007 C-III–583
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-III–584 10/2007
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
10/2007 C-III–585
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-III–586 10/2007
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. Y4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (concluded)
10/2007 C-III [M-1002] 587

APPENDIX Y M-1002
Exhibit 2
Addendum—September 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. Y5 D.V. 2007 addendum—additional commodity requirements

C-III [M-1002] 588 10/2007
M-1002 APPENDIX Y
Retention Time By
Item Document AAR Ref.a/
Proponent
1. Mill test certificates 5 years
1a. Plate material identification reports (consistent with radiograph 5.1.4 5 years
retention time)
2. Radiographs and radiotapes R19.1.5 5 years
3. Postweld heat treatment record (consistent with radiograph retention W17.0/R20.0 5 years
time)
4. Welder performance qualification test results W10.3/W12.8 Until requalified
5. Welding procedure qualification reports W10.3/W13.6 Until revised
6. Calibration for tank capacity 1.3.8 Life of car
7. Impact, corrosion, and hardness tests when required by specification W9.0 5 years
(consistent with radiograph retention time)
8. Certificate of tank test Appendix D Until next tank test
9. Certificate of pressure relief valve test Appendix D Until next pressure
relief valve test
10. Certificate of interior heater coil test. Note: Test of exterior coils is not a Appendix D Until next interior
specification requirement heater coil test
11. Original and subsequent tank car certificates of construction 1.3.5/1.4.4 Life of car
Form AAR 4-2
12. Exhibit R-1 and R-2 forms describing modification or repairs 1.3.5/1.3.15/ Life of car
R4.3/R4.4
13. Pressure relief device and other device certificate for approval (Forms 1.4.5/1.4.6 10 years
AAR 4-3 and 4-5). (Precedent approvals are acceptable for 10 years,
then must be resubmitted using Form AAR 4-7)
13a. Renewal of approval for valves and fittings (Form AAR 4-7) 1.4.7 10 years
14. Final product test and inspection report (Form AAR 4-6). (Service trials 1.4.9 2 years
for devices in hazardous or regulated commodities are for 2 years)
15. SS-1, SS-2, and SS-3 forms for stub sill inspections 1.3.15/R6.0/ Life of car
O&M Circ. No. 1/
CPC-1097
16. Tank car service trial report (Form AAR 4-4). 1.4.8 Duration of trial
17. Certified inspector’s reports for Class DOT-107A tanks 1.4.4.2 Life of tank
18. Drawings used as precedent for repairs. (Drawings used for precedent 1.4.2.3 10 years
approval must be resubmitted every 10 years.)
19. Certification and recertification of facilities. (Facilities must be recertified B6.1 6 years
or reregistered every 6 years.)
19a. Registration and reregistration of facilities B6.2 6 years
20. General arrangement, tank and fittings arrangement drawings. 1.3.15 Life of car
21. Qualification of tank cars Appendix D/49 Until next
CFR 180.517(b) qualification
22. Service reliability assessment data Appendix U Life of car +10 years
a/ Letter preceding a paragraph reference specifies an appendix of this manual.
Fig. Y6 C-6993 minimum retention time for various tank car documents
10/2007 C-III [M-1002] 589

APPENDIX Y M-1002
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 AAR’s 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

Phone (202) 639-2147; FAX (202) 639-2930; e-mail pkinneco@aar.org
Fig. Y7 CPC-1097 stub sill inspection program—new Form SS-3 (page 1 of 5)
C-III [M-1002] 590 10/2007

M-1002 APPENDIX Y
Form SS-3 Report of tank Car Stub Sill Inspection
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

10/2007 C-III [M-1002] 591
APPENDIX Y M-1002
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
C-III [M-1002] 592 10/2007

M-1002 APPENDIX Y
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 ¼ inch and recorded in decimal format (e.g.: 3 ¾=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
10/2007 C-III [M-1002] 593

APPENDIX Y M-1002
31.) Inspector’s name

32.) Car owner representative’s 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
C-III [M-1002] 594 10/2007

M-1002 APPENDIX Y
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 car’s 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. Y8 CPC-1114 requirements for SS-3 inspections of tank car stub sills (page 1 of 4)
10/2007 C-III [M-1002] 595

APPENDIX Y M-1002
CPC-1114
May 10, 2001
Page 2
As information, the amended stub sill inspection program description is attached.
Sincerely,
P. G. Kinnecom

C-III [M-1002] 596 10/2007

M-1002 APPENDIX Y
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.

10/2007 C-III [M-1002] 597

APPENDIX Y M-1002
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 AAR’s 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 AAR’s 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).

C-III [M-1002] 598 10/2007

M-1002 APPENDIX Y
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 manufacturer’s 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. Y9 CPC-1116 Shop practices for installation and maintenance of bottom outlet valves (page 1 of 2)
10/2007 C-III [M-1002] 599

APPENDIX Y M-1002
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. Y9 CPC-1116 Shop Practices for Installation and Maintenance of Bottom Outlet Valves (page 2 of 2)
C-III [M-1002] 600 10/2007

Back-of-Book FormsApplication for Approval and Certificate of Construction
APPLICATION FOR APPROVAL AND CERTIFICATE OF CONSTRUCTION

Page 1 of
1 APPROVAL REQUESTED OF: PRECEDENT 2 TYPE: CONSTRUCTION WELDED REPAIRS 3 AAR NO.
NONPRECEDENT ALTERATION OTHER 4 DATE:
CONVERSION 5 APPLICANTS NO.
6 APPLICANT: 7 TANK SPECIFICATION:
8 STENCILED SPEC.:
9 REPORTING MARKS & CAR NUMBERS 10 NUMBER OF CARS
11 Initial commodity 12 Density, lb, per gal

13 Full water capacity, gal 14 Dome capacity or outage, gal
15 Material type and grade—heads 16 Material type and grade—shell
17 Material thickness—heads, in. 18 Material thickness—shell, in.
19 Lining type 20 Inside diameter—center, in.
21 Inside diameter—end rings, in. 22 Head radius, main, in. (if not 2:1)
23 Test pressure, psi 24 Insulation type
25 Insulation thickness, in. 26 Thermal conductivity, Btu-in/hr—ft2-F
27 Type and number of pressure 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, in. 34 Est. light weight, lb
35 AAR clearance diagram 36 Rail load limit, lb
37 Truck capacity, tons 38 Head shields
Notes:
Original Certificate_______________________________
Builder ________________________________________
Date__________________________________________
Former lading __________________________________
The Following Prior Approvals Apply:

The Following Drawings Apply: Drawing Number Drawing Number Application/Certificate No.
39 General Arrangement……………………………
40 Tank Arrangement………………………………
41 Reinforced 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: __________________________________________

SIGNATURE _______________________________________________
TITLE_____________________________________________________
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 ______________________________________________________

AAR No. __________________________
Applicant’s No. _____________________
Date _____________________________
APPLICATION BY: __________________________________________

SIGNATURE _______________________________________________
TITLE_____________________________________________________
Date Approved _____________________________________________

(signature) on behalf of the Tank Car Committee
Form AAR 4-2.1 Revised 12/1/00 Page of

Application for Approval of Pressure Relief Device
APPLICATION FOR APPROVAL OF PRESSURE RELIEF DEVICE
AAR NO. PRD-

Applicant’s No.
APPROVAL REQUESTED OF AAR TANK CAR COMMITTEE Date
Device identification No.
Applicant
1. Manufacturer
Address
2. Test facility 3. 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. Commodities
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
Date Approved
* 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.

AAR Tank Car 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. Applicant’s No. 2. Device ident. No. 3. Date initial installation

5. Number cars authorized to applicant Number of cars this report
This Report 10. To Date

9. Distance Distance
6. Reporting Marks 7. Commodity 8. Loaded Loaded
Trips Miles Km Trips Miles Km
AVERAGES
11. Loading temperature ºF ( ºC) 12. Unloading temperature ºF ( ºC)

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.
*NOTE: This report to be furnished at six month intervals, April 1st and October 1st, and submitted to the Director. Failure to submit
report may result in cancellation of service trial permit.
Submitted by Title

Application for Approval of Valves and Fittings
APPLICATION FOR APPROVAL OF VALVES AND FITTINGS

Applicant AAR No.
Description of Device
Applicant No. Device Ident. No. Date

1. Manufacturer
Address City State Zip
2. Test facility Address
TEST PROCEDURE: 5. Weight or mass of device lb. (_______ kg)
6. Description of prototype testing:
7. Description of production testing:
8. Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
________ __________ºF _________psi ________ __________ºF ________psi ____________
________ __________ºC ________kPa ________ __________ºC _______kPa ____________
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
________ __________ºF _________psi ________ __________ºF ________psi ____________
________ __________ºC ________kPa ________ __________ºC _______kPa ____________
9. Cycles Min. Pressure @ Temp. Cycles Max. Pressure @ Temp. Test Medium Remarks
________ __________psi _________ºF ________ _________psi ________ºF ____________
________ _________kPa _________ºC ________ _________kPa ________ºC ____________
Cycles Min. Pressure @ Temp. Cycles Max. Pressure @ Temp. Test Medium Remarks
________ __________psi _________ºF ________ _________psi ________º F ____________
________ _________kPa _________ºC ________ _________kPa ________ºC ____________
10. Initial commodity (or commodity type) __11. Flow rate (if applicable) __gpm (_________L/min)
Drawing Number Precedent

Applicable drawings Material latest revision Drawing Number Application/Certificate
12. Device application . . . . . .
13. Device assembly . . . . . . . .
14. Device details . . . . . . . . . .
15. 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
Date Approved
Form AAR 4-5 Revised 12/1/2000 Subject to AAR Service Trial No. _____________
Final Product Test and Inspection Report
FINAL PRODUCT TEST AND 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 from latest Form AAR 4-4 dated
Total load/unload cycles Total loaded mileage
Total service time
8. Teardown data Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

From car number………………
Last lading…………………….
Model number…………………
Serial number………………….
Test pressure, psi (kPa)………..
Test temperature, °F (ºC)……….
Test medium…………………...
Cycles………………………….
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
(Signature) (Signature)
Title Title
Company Company
13. APPROVAL AAR Tank Car Committee
Date approved
NOTE: The AAR Tank Car Committee reserves the right to designate an independent observer to be present during test and teardown activity.
Form AAR 4-6 Revised 10-17-86

Application for Renewal of Approval for Valves and Fittings
APPLICATION FOR RENEWAL OF APPROVAL FOR VALVES 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 12/1/2000
Quality Assurance Nonconformance Report QA-7.1

8/1/07
Specification for Quality Assurance
M-1003
Rev.
8/1/05 QA-7.1
ASSOCIATION OF AMERICAN RAILROADS

QUALITY ASSURANCE NONCONFORMANCE REPORT
7.3.4.1 Serial No.
7.3.4.2.1 Date
7.3.4.2.1 Reporting 7.3.4.2.1 Reporting

Company Company Location
7.3.4.2.2 Contractor 7.3.4.2.2 Contractor Plant

Location
7.3.4.2.3 Item Description 7.3.4.2.3 AAR Spec. Code

or Standard No.
7.3.4.2.4 Contractor Part,

Pattern No., and/or Drawing
Ref
7.3.4.2.5 Quantity Received 7.3.4.2.5 Quantity Inspected
7.3.4.2.5 Quantity Rejected 7.3.4.2.6 Material inspected If No, explain

by Contractor?
Yes No
7.3.4.2.7 Serial Number, 7.3.4.2.8 Nonconformance Description 7.3.4.2.9 Disposition of Item

Identification Mark, or Car (Returned, Repaired, Scrapped,
No. Other)
7.3.4.3 Verify copy sent to Contractor Information:

contractor
Name and Title _________________________________________________________________________________________
Company Name _________________________________________________________________________________________
Street _________________________________________________________________________________________________
City, State, ZIP __________________________________________________________________________________________
Person initiating claim Name

Signature Address
Title City, State ZIP
Phone
Send to AAR QA Program Coordinator, TTCI, 55500 DOT Road, Pueblo, CO 81001 or qa@aar.com.
8/1/07
Quality Assurance Nonconformance Response Report QA-7.2

8/1/07
Specification for Quality Assurance
M-1003
Rev.
8/1/05 QA-7.2
ASSOCIATION OF AMERICAN RAILROADS

QUALITY ASSURANCE NONCONFORMANCE RESPONSE REPORT
7.6.2.1 Serial No.
7.6.2.2 Date
7.6.2.3 Contractor 7.6.2.4 Reporting Company
7.6.2.3 Location 7.6.2.4 Location
7.6.2.5 Date QA-7.1 was filed 7.6.2.6 Quantity Rejected
7.6.2.7 Description of nonconformance

(from QA-7.1)
Action Required Description of Action Taken Date
7.6.2.8 Clearly define the nonconfor-

mance that led to the rejection.
7.6.2.9 Clearly define the actions taken

for disposition.
paragraph 7.6.2.10 Clearly define the

root cause(s) that resulted in the non-
conformance.
7.6.2.11 Clearly define the corrective

action(s) taken that will eliminate the
root cause(s).
7.6.2.12 Clearly define the follow-up

plan(s) that will ensure the effective-
ness of the corrective action(s) taken
in its/their permanence.
Note: Contractor is not confined to using only the spaces above and is encouraged to use attachments.
7.6.2.13 Ensure that the QA-7.1 report initiator has been sent a copy of the completed QA-7.2, including a copy of the original QA-7.1 report. Also
ensure that the customer’s Purchasing and Mechanical Department managers have been sent a copy of the QA-7.1 and completed QA-7.2.
Signed by Management Representative Title
Send original to AAR QA Program Coordinator, TTCI, 55500 DOT Road, Pueblo, CO 81001 or qa@aar.com. Include a copy of the original QA-7.1 report.
8/1/07
Exhibit B-1 Subcontractor Evaluation Sheet

M-1002 APPENDIX B
EXHIBIT B–1
SUBCONTRACTOR EVALUATION SHEET
Each facility shall complete and retain an original copy of this form for each listed Appendix B subcontractor. A
company representative responsible for the activity shall attest and affirm, by signing this form, 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.
SUBCONTRACTOR COMPANY NAME
SUBCONTRACTOR COMPANY ADDRESS
SERVICE, PRODUCT, OR EQUIPMENT

PROVIDED BY THE SUBCONTRACTOR
SUBCONTRACTOR COMPANY CONTACT
COMPANY REPRESENTATIVE (ATTESTING)
DATE VERIFIED
DATE OF EXPIRATION
SUBCONTRACTED ACTIVITY
(PLEASE CHECK ALL THAT APPLY) PERSONNEL PROCESSES EQUIPMENT
FOR EACH CHECK ABOVE, PLEASE EXPLAIN HOW THE COMPANY REPRESENTATIVE RESPONSIBLE FOR THE ACTIVITY VERIFIES THAT THE
SUBCONTRACTOR UNDERSTANDS AND CONFORMS TO THE REQUIREMENTS OF THE ASSOCIATION OF AMERICAN RAILROADS’ SPECIFICATIONS FOR
TANK CARS, M-1002.
PERSONNEL:
PROCESSES:
EQUIPMENT:
10/2007
Exhibit B-2 AAR Tank Car Committee Shop Evaluation

M-1002 APPENDIX B
EXHIBIT B–2

To: Executive Director—Tank Car Safety
Facility________________________________ Station Stencil ____________________________________
Facility Contact ___________________________________________________________________________
Location: Address _________________________________________________________________
City __________________ State ____________________Phone___________________
Requested Class: A B C D
Material Groups: 1 2 3 4 7 Including/Excluding TC128
Size of Workforce_______________________ Shop Dedicated to:
Evaluation
Element Remarks
Yes No
Conformance to building specifications
Welding, fabrication, and construction
practices
Quality control
Facilities
Operations
Test devices
Maintenance
Engineering and drafting
Evaluator’s comments:
RECOMMENDATION: I/We inspected this facility on _____________ (date) and found/did not find the
equipment, personnel, and records to be as listed in the Request for Certification dated ____________.
I/We recommend/do not recommend certification of the facility as Class _____________,
Material Groups _____________, including/not including TC-128.
I/We recommend conditional/unconditional certification.
Inspector: _________________________________ ____________________________________
Title: _____________________________________ ____________________________________
Organization:______________________________ ____________________________________
Date: _____________________________________ ____________________________________
Signature:_________________________________ ____________________________________
10/2007
M-1002 APPENDIX B
EXHIBIT B–2

(CONTINUED)
Facility Evaluation
Element Remarks
Class Yes No
1.0 CONFORMANCE TO BUILDING
SPECIFICATIONS
A. Where AAR approval is required by
specifications, sublet fabrication or A, B
manufacture must be awarded to
manufacturers holding appropriate
approval.
B. Materials must be identified when
transferred from storage to shop pri- A, B, C, D
or to processing.
2.0 WELDING, FABRICATION AND
CONSTRUCTION PRACTICES
A, B, C, D
A. The procedures outlined in Appendix
W of M-1002 must be followed.
B. Welding procedures and welding pro-
cedure qualifications must conform A, B, C, D
C. Tank car materials must conform to
A, B, C, D
Appendix M of M-1002.
D. Welder qualifications must conform
A, B, C, D
3.0 QUALITY CONTROL
A. Quality assurance program must be A, B, C, D
maintained in accordance with AAR
Specification M-1003.
B. Inspectors must have the following
equipment available and in use:
A, B, C, D
Welding gauges
Tag system
C. There must be testing equipment or
a testing service available to verify
A, B, C, D
conformance of material to specifica-
tions.
D. Names, titles, and duties of shop and
quality control personnel must con-
A, B, C, D
form to the application. List those in-
terviewed.
E. Welding inspector and non-
destructive examiners must be
A, B, C, D
available in accordance with Appen-
dix B, paragraph 4.1.
10/2007
M-1002 APPENDIX B
EXHIBIT B–2

(CONTINUED)
Facility Evaluation
Element Class Remarks
Yes No
F. Check Exhibit B–1 subcontractor
A, B, C, D
documents for completeness.
4.0 FACILITIES
A. The facility must have a transfer ta- A, B
ble or other mechanism to simulate
AAR minimum curve requirements.
B. The facility must have possession of
or access to scale for weighing of cars.
A, B
(Capacity, length of scale, and certifi-
cation to be provided by facility.)
C. The facility must have designated
level track for adjustment of side A, B, C
bearings and coupler height.
D. The applicant must have necessary
and operable equipment on premises A, B, C, D
to perform the intended work.
E. There must be proper storage for
welding electrodes, fittings, valves, A, B, C, D
brake valves, and brake cylinders.
F. There must be sufficient flux and/or
rod ovens in use to support the
A, B, C, D
operations per Appendix W and AWS
D15.1.
G. Radiography equipment and
postweld heat treatment facilities A, B, C, D
must be available.
H. Radiographs must meet the require-
ments of Appendix W,
A, B, C, D
paragraph 11.0, and must be stored
in an acceptable manner.
I. Radiographs must be maintained for
A, B, C, D
the required time.
5.0 OPERATIONS
A. Raw material must be blocked and A, B, C, D
handled to prevent permanent
distortion.
B. The facility must have yard space,
handling equipment, and other
A, B, C, D
equipment to store and handle mate-
rials.
10/2007
M-1002 APPENDIX B
EXHIBIT B–2

(CONTINUED)
Facility Evaluation
Element Class Remarks
Yes No
C. Work in progress must comply with
M-1002:
Welding
Stenciling
A, B, C, D
Lining
Repairs
Nondestructive Testing
Other
6.0 TEST DEVICES
A. The facility must have AAR-ap- A, B
proved brake shoe force measuring
devices available.
B. The facility must have hand brake
A, B
force measuring device available.
C. The facility must have single car test
A, B, C
device.
D. The single car test device must be
verified in accordance with the latest A, B, C
AAR requirements.
E. The facility must have a brake pipe
restriction test device and calibrat- A, B
ing test coupling.
F. The facility must have available a
brake pipe restriction test device and C
calibrating test coupling.
G. The brake pipe restriction test device
must be tested in accord with the lat- A, B, C
est AAR requirements.
H. The facility must have calibrated hy-
drostatic test equipment (where re- A, B, C, D
quired.)
I. The facility must have calibrated
pressure relief valve testing equip- A, B, C, D
ment available (where required).
7.0 MAINTENANCE
A. Equipment, tools, welding machines, A, B, C, D
etc., as submitted must be main-
tained in proper working order.
8.0 ENGINEERING AND DRAFTING
A. The company must have in-house en-
gineering and drafting capability A, B
with a manager who holds a degree
in engineering.
10/2007
M-1002 APPENDIX B
EXHIBIT B–2

(CONTINUED)
Facility Evaluation
Element Remarks
Class Yes No
B. Personnel responsible for supervis-
ing engineering, production, repair,
testing and quality assurance must A, B, C, D
have knowledge of the applicable
codes and specifications.
C. The facility must have a current li-
brary of specifications (latest revi-
sions) of all manuals applicable to
work being performed, such as:
AAR Field Manual
AAR Office Manual A, B, C, D
AAR Manual of Standards, M-1002
FRA or TC Safety Appliance Standard
AAR Circulars
BOE Tariff 6000 or 49CFR (US only)
CGSB Standard 43.147 (Canada only)
TDG Regulations (Canada only)
D. The company must have in-house de-
sign engineers or it must consistent-
A, B
ly use consultants qualified by
registration or experience.
E. (The facility must have personnel ca-
pable of supervising, evaluating and
A, B, C, D
coordinating outside shop detail
drawings and/or specialty drawings.
9.0 OTHER (GIVE DETAILED
DESCRIPTION)
10/2007
Exhibit B-3 Registration for Class F, G, and L Facilities

M-1002 APPENDIX B
EXHIBIT B–3
REGISTRATION FOR CLASS F, G, AND L FACILITIES

Executive Director—Tank Car Safety
50 F Street N.W.
Request to register the facility or operation designated below that performs the work as outlined
in this registration, in accord with federal regulations at 49 CFR 180 and Appendix B of Specifica-
tion M-1002, Specification for Tank Cars.
This is to attest that the facility or operation described below meets the compliance requirements
of 49 CFR 179.7 and M-1002, Appendix B, paragraph 3.4, per the attached checklist.
Company
Facility
Address
Phone number Fax number
Activities performed at this facility:
Class F
Class G
Class L
Signed Title
Print name Date
Signature for Executive Director—Tank Car Safety
Date registered Station stencil (assigned)
10/2007
M-1002 APPENDIX B
EXHIBIT B–3
(CONTINUED)
(1) (2)
Company Document
1.0 SCOPE
Scope of work for which you are requesting registration.
2.0 ORGANIZATION
A. Responsibilities of QA personnel defined, highlighting the following
functions: performance and management of QA work and verifica-
tion of conformance to QA requirements (identifying, recording, and
correcting nonconformances).
B. Positions to which each of the tasks shown in 2.0A are assigned and
each position’s relationship to the organization (organization chart).
3.0 INSPECTION AND TEST PLAN
A. Inspection and test plan.
B. Where subcontractor’s services will be utilized
C. Methods employed by contractor to verify subcontractor quality per-
formance.
D. Verification methods to be employed for special process procedures.
4.0 DOCUMENT CONTROL
Current issues of applicable documents are available and accessible at all
applicable functional areas. A list of applicable publications required to
keep current.
5.0 MEASURING AND TEST EQUIPMENT
A system is provided to ensure that all measuring and test equipment and
devices used to verify quality and monitor special processes are controlled,
maintained, and properly documented.
6.0 INCOMING INSPECTION
Provisions are made to inspect, test, and identify incoming items as
required by the inspection and test plan.
7.0 FINAL INSPECTION
Provisions are made to inspect, test, identify, and document the final items
as required by the inspection and test plan.
8.0 SPECIAL PROCESSES
Provisions are made to ensure that the qualifications of personnel, process-
es, and equipment comply with requirements of applicable specifications,
codes, and standards and are properly documented.
9.0 QUALITY RECORDS
Provisions are made to maintain quality records as evidence that the refer-
ence drawing number and revision number or part number of the item are
identified.
10/2007
M-1002 APPENDIX B
EXHIBIT B–3
(CONTINUED)
(1) (2)
Company Document
10.0 NONCONFORMANCE
Provisions are made for the retention, evaluation, and disposition of all
nonconforming items, including those of subcontractors.
11.0 INTERNAL QUALITY AUDITS
Internal quality audits are planned, scheduled, and documented at least
once per year to verify compliance with specifications.
12.0 TRAINING
A. Approved procedures for identifying training needs and providing
training for all personnel involved in quality have been established.
B. Personnel performing specific tasks are qualified on the basis of ap-
propriate education, training, and/or experience.
C. Records of training are maintained
D. Measures to ensure that personnel are aware and knowledgeable of
their specific responsibilities for quality have been defined.
E. The necessary instruction and means whereby those personnel can
develop, achieve, and maintain proficiency are provided.
13.0 DESIGN CONTROL
A. Design input requirements, including contract review activities, are
documented, clarified, and reviewed for adequacy.
B. The design outputs meet design input requirements.
10/2007

12/1/00 Specifications for Tank Cars
APPENDIX D M-1002

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 dis-
tress.
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
10/2007
Exhibit R-1 Report of Tank Repairs, Alteration, or Conversion
EXHIBIT R-1 REPORT OF TANK REPAIRS, ALTERATION OR CONVERSION

1. To AAR Executive Director-Tank 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: (Ref. 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 QA Representative: Title:

Car Owners Representative: Title:
Date approved by Car Owner:
Rev. 12/1/2000
10/1/03
Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
M-1002 APPENDIX R

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 Shell—Exterior (C)-Tank Head—Interior (D)-Tank Head—Exterior (E)-Cen-
ter Sill—Web (F)-Center Sill—Flange (G)-Center Sill—Both (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)-Weld—Bolster 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)-Corrosion—Random Pits (E)-Corrosion—Grouped
Pits (F)-Corrosion—Adjacent to Weld (G)-Corrosion—General (H)-Other (Explain in Item 24. Comments)
(I)-Corrosion—Bathtub 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)-11.1 (D)-11.2 (E)-11.3 (F)-11.4 (G)-11.5 (H)-13.2 (I)-Replaced in Kind (J)-Precedent Certif-
icate of Construction, Number: a. ________; b. ________; c. ________; d. ________; e. ________; f. ________
(K)-12.2 Buckles (L)-Rule 82 Weld Sill (M)-Rule 57 (O)-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: Original—Car owner; Diskette copy—AAR
10/2007

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., “C2—3-in. crack in weld”)
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
25. Disposition of Car: ____________________________________________________________________
Inspected by: ____________________________________ Title: __________________________________
rev 12/00

M-1002 APPENDIX Y
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
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

APPENDIX W M-1002

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.

M-1002 APPENDIX W
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.)


APPENDIX W M-1002

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 __________________________________________ ________________________________________________
________________________________________________ ________________________________________________

M-1002 APPENDIX W
PQR No. _______________________

REDUCED SECTION TENSILE SPECIMEN TESTS
Ultimate Ultimate Type of
Specimen Total Load Unit Stress Failure &
No. Width Thickness Area lb. psi Location
ALL—WELD—METAL 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 _________________________________________________________________________________________________
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Welder’s 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

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
Q Manual or Semiautomatic Variables for Each Process (W12.4) 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Q Machine Welding Variables for the Process Used (W12.2)
Guided Bend Test Results
Guided Bend Tests Type ( ) Fig W5C (Side) ( ) Fig W5A&B (Trans. R & F) ( ) Fig W5B (Long, R & F)
Type (Side, Root, Face) Result Type (Side, Root, Face) Result
Visual examination results
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. x 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
10/2007

M-1002 Section C-III Specifications For Tank Cars 2007

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M-1002 Section C-III Specifications For Tank Cars 2007

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10/2007

Association of American Railroads

SPECIFICATIONS FOR TANK CARS

ISSUE OF OCTOBER 2007

The Association of American Railroads

Copyright © 2007 by the Association of American Railroads (AAR)

ORDERS FOR Publications Department

THIS PAGE LEFT BLANK INTENTIONALLY

MEMBERS OF THE AAR TANK CAR COMMITTEE

Appendix Subject Page

THIS PAGE LEFT BLANK INTENTIONALLY

INTRODUCTIONS, APPROVALS, AND REPORTS

Paragraph Subject Page

10/2007 C-III [M-1002] 1

Paragraph Subject Page

C-III [M-1002] 2 10/2007

CHAPTER 1. INTRODUCTIONS, APPROVALS, AND REPORTS

10/2007 C-III [M-1002] 3

1.1.3 List of Specifications

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 — —

C-III [M-1002] 4 10/2007

Table 1.1 List of tank car specifications (page 2 of 5)

AAR-211A100ALW1 11-10-66 11-10-71 — —

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/

DOT-105A600W 1-7-41 12-31-71 — i/

10/2007 C-III [M-1002] 5

Table 1.1 List of tank car specifications (page 3 of 5)

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/

ICC-111A60ALW 7-19-59 12-19-64 5-27-67 —

DOT-111A60W1 2-17-63 12-31-71 — —

C-III [M-1002] 6 10/2007

Table 1.1 List of tank car specifications (page 4 of 5)

ICC-111A100ALW 5-22-65 — 5-27-67 —

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/

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-112J500W 10-19-77 7-13-78 — k/

DOT-112S340W 10-19-77 7-13-78 — k/

Date Approved ________________________________