By Safety Management Group
Trains have long fascinated and frustrated people. For every child who hypnotically watches a long train full of colorful freight cars roll by, there a driver who’s running late and wishes railroads had never been invented.
Railroads play a key role in America’s economy, and as trains become more energy-efficient, a larger share of freight is being transported by rail. The polished steel wheel rolling on polished steel rail is an amazing efficient and economical way to move large loads over long distances.
It’s easy to forget, however, that railroading is an inherently hazardous business. Today’s average freight car weighs more than 250,000 pounds when fully loaded. Many of those cars transport potentially deadly chemicals. Some even carry casks of spent nuclear fuel and radioactive earth from old nuclear energy sites.
Whenever workers and railcars interact, there’s a potential for serious injury and death. A worker who becomes trapped between two cars or falls under a moving car can be crushed or lose limbs in a matter of seconds. Workers who fail to follow proper safety procedures when loading and unloading cars can find themselves injured by the contents of those cars. And when procedures regarding handbrakes, chocks, and other retention devices are not observed, an unattended railcar may become a deadly weapon that accelerates quickly and can slam into buildings, other railcars, vehicles, or any other obstacle.
Design of railcars
A key difference between railcars and most types of vehicles workers will encounter is that the wheels are not attached to the car’s body. Instead, axles are placed into “truck” assemblies that sit underneath center plates and bearings. The truck is allowed to move freely beneath the car’s body at moves through curves, switches, and imperfections in the tracks, while the weight of the car itself and any load keeps the car in place.
However, it also means that cars must be carefully loaded and properly secured to ensure that the car will stay in balance. Just as a dump truck is at great risk of rollover if its load is shifted to one side or another, having all of the weight on one side might cause a railcar to tip over on a curve.
If the car is somehow lifted off the truck (even briefly), such as the result of a minor accident while it’s being handled, it must be inspected by qualified railroad personnel to ensure that the trucks are correctly seated in the center plates.
Basic awareness and alertness
When working around railcars, an alert worker who is aware of the potential hazards is a much safer worker. While we don’t think of trains as quiet, because most locomotives are fairly noisy, railcars with well-lubricated axles can roll very quietly down the track. That’s why it’s critical to expect trains to appear on any track, at any time, with little or no warning. It’s also why workers should never stand or sit on rails, or walk between them. Rails may be slick due to lubricated oil or moisture, so walking on top of the rail puts workers at risk of slipping off and falling.
As a general rule, workers should maintain a safe distance from tracks on the worksite. If they need to cross tracks, they should always look both ways, even if it’s been a while since the tracks were used. Once they’re sure that no trains or other equipment are moving on the track, they should cross at right angles to the track. If railcars on parked nearby on the track, they should cross at least one car length away, in case the cars are actually moving slowly.
Climbing over train cars or their couplers may seem like a handy shortcut, but it’s extremely dangerous. Couplers provide a loose connection, and when trains stop, slack typically forms between cars. If the train starts moving, that slack may suddenly run out or in, causing a significant movement within the train. If a worker is on the coupler, drawbar, or any of the related hardware when that happens, he or she could suffer a serious pinching or crushing injury.
If equipment on the train needs to be adjusted, use the proper tools. For example, trying to adjust coupler height with one’s foot is a way to lose a limb. If you need to climb up on a car’s ladder or stand on any of the walkways, be sure to maintain three-point contact at all times.
Watch the tracks, too, especially around switches, derails, and other moving equipment. When a switch is thrown, the hydraulic pressure is usually strong enough to crush a foot or hand that inadvertently gets in the way. The best advice is to maintain a safe distance from all moving parts of a switch.
Worker protection
The key to safety during railcar operations is communication. Effective communication ensures that all employees know where their fellow employees are located and what they’re doing. While some companies may issue radios to employees who work around trains, many use standard hand signals. It’s a good idea to use the same hand signals as the railroad serving the company to ensure that there isn’t any confusion about what a particular gesture means. All personnel working near railcars should wear high-visibility apparel such as reflective vests.
Employers should post protective devices as needed along the rails. For example, if there are locations where there is limited clearance between railcars and a structure, signs should warn that there is no room for a worker. Similarly, if there are places where visibility is limited and workers should not cross the tracks, guardrails will add an extra level of safety.
If an employee has to enter a train car to facilitate unloading or make emergency repairs, the car should be treated as a confined space, using the standard safety procedures for such spaces.
Getting ready to move
Railcars should be moved only with equipment that is specifically designed for doing so, such as locomotives or trackmobiles. Using tractors, loaders, or other jobsite equipment that is not specifically approved for moving railcars is extremely dangerous to workers, and may damage the railcars (not to mention the equipment itself). The operator should carefully inspect the locomotive or other equipment used to move cars before each use, with a special focus on testing the brakes and other safety devices.
The operator must not make any movement until he or she is completely certain that all workers are in safe locations and know that the train will begin to move. In addition, cars should be moved at a safe speed that will allow a gentle stop before the end of the track.
All car doors and other movable surfaces such as hopper gates must be closed before cars can be moved. If workers are not sure about how to close doors and gates on a particular car, they should contact the railroad for instructions. All cars must be securely coupled together, and all wheel chocks and other devices used to secure wheels must be removed before the operator releases the brakes.
While it may be tempting for workers to climb onto a car and ride along, it’s very dangerous to do so. In fact, OSHA rules prohibit riding on moving equipment unless company policy and the specific tasks being performed require workers to do so.
About stopping
Train cars have two separate braking systems: an air brake that is operated from the locomotive and used for control of a train while it is moving, and a mechanical handbrake that is applied to ensure that a car doesn’t move when it is stopped for loading, unloading, or storage. For added protection, wheel chocks may be used to prevent accidental movement.
Most workers will not interact with air brakes, with the exception of connecting the air hoses between cars. The hoses must be connected properly so that the train’s operator can release the brake before moving.
In most cases, the handbrakes are applied by rotating a metal wheel at the end of the car. Once that wheel is fully tightened, the worker should verify that the chain linking it to the brake mechanism is taut, and that the brake pads are securely places against the wheels.
If either of a railcar’s braking systems is inoperative or damaged, the car should not be used, and the railroad should be notified. The car should be marked to show that there is a problem (railroads refer to this “bad ordering” the car).
Safe loading and unloading
Again, a railcar must be carefully balanced to prevent it from falling off the track. As it is being loaded, be sure to keep the weight of the contents as equal across the car’s width as possible. A car should never be loaded beyond its legal capacity, and the contents should not extend beyond the sides of the car. Loads that may move should be blocked and secured, and any loose materials should be removed and cleaned up before the car is ready to travel.
Unloading a car can also create hazards, so proper procedures should be followed. In most situations, the car should be mechanically secured to ensure that it won’t move or tip over as the contents are removed. As with loading, contents should be removed evenly across the car’s width to minimize the chances of tipping. Bulk materials such as cement, grains, sand, and dry chemicals may interfere with the ability to open and close gates and doors.
Railcar doors are normally closed very tightly, and trying to open them by hand may lead to injury. Instead, workers should use tools such as pneumatic car door openers that allow for greater torque. Before opening (or closing) a door, check to make sure that hinges are properly placed in their tracks, and that any gearing mechanisms are operating correctly. You should also be alert to the possibility that a load may be leaning against the door.
When unloading hopper cars with gate locks, make sure the locks have been released before trying to open the gate. When the load has been emptied, close the gate securely, engage lock, and then verify that it is properly closed and locked.
What’s that blue flag?
While working along railroad tracks, you may encounter a small blue metal flag or blue light affixed to the track. Federal railroad regulations require that a blue flag or light be placed on the track when people are working on a railcar. Trains are prohibited from passing blue flags. In addition, only authorized railroad workers are allowed to remove those flags. (The rules are similar to the lockout/tagout restrictions used with electrical equipment.)
Other railcar hazards
Some situations may increase existing hazards or create new ones. For example, rain, snow, and ice can increase the potential for slips and falls, and strong winds can cause railcars to sway. Loading and unloading at night demands extra care as well, especially if lighting is poor or unavailable. And, as with nearly every task, a worker who is tired is less likely to follow proper procedures, so provide additional supervision as needed.
The Right Track for Railcar Safety
