Abstract:
A stack of elongate elements, such as lengths pipes, in a container, such as a gondola railroad car, that has an interior length greater than the length of the individual pipes. The pipes are stacked so that some of the pipes in the stack have end portions adjacent one end of the container and other pipes have end portions adjacent the other end of the container, such that the stack has an overall length approximating the interior length of the container. End lashings are secured around the end portions of the pipes and apply a pinching pressure to the end portions. A plurality of interior lashings are secured around the pipes interiorly of the end portions with each interior lashing including at least one pipe that is also included within another interior lashing.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a stack of elongate elements in a container and to a method of stacking. More particularly, the present invention relates to stacking of elongate elements in a container having an interior length greater than the length of the individual elements with the individual elements stacked in a manner that provides a stack having an overall length approximating the interior length of the container. 
       BACKGROUND OF THE INVENTION 
       [0002]    Elongate elements, such as lengths of pipe or other types of cylindrical conduits or rods, are commonly loaded in containers for shipment, such as in gondola railroad cars or open top truck beds. Usually, the elements are of lengths less than the interior length of the container. As a result, during transport when there is abrupt stopping and starting, such as during the back-and-forth stopping and starting of railroad freight cars in a hump yard in making up a train, the elements in the stack shift suddenly and potentially cause damage to the ends of the container and disrupt the relative position of the elements in the stack. It is known to stack railroad ties in the ends of the cars to fill the space between the ends of the pipes and the end wails of the car. Also, it is known to use steel or fabric lashings encircling stacks of pipes in gondola cars to restrict lengthwise shifting of the pipes, such as disclosed in AAA Open Top Loading Rules Manual (12/2007), pages 236-241, but such lashings do not provide sufficient restraint to reliably prevent damaging shifting. It is to solving this problem that the present invention is directed. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention provides a solution to the problem of shifting of elements in a container causing damage to the ends of the container in which they are stacked. 
         [0004]    Briefly described, in one form, the stack of the present invention is formed from horizontal lengths of elongate elements of substantially equal length disposed for stacking in a container having an interior length greater than the lengths of the individual elements. The elements are stacked in horizontal rows with the end portions of one row or rows extending beyond the ends of another row or rows, so that the end portions of a row or rows is adjacent one end of the container and the opposite end portions of another row or rows is adjacent the other end of the container. Means, such as lashings encircling the stack, are provided for restraining lengthwise movement of the rows of elements. With this arrangement, the close proximity of the ends of rows to the opposite end walls of the container precludes damaging shifting of the elements during sudden stopping of the container. 
         [0005]    Preferably, the stack includes a first row or rows of elements having end portions adjacent one end of the container, a second row or rows of elements having end portions adjacent the opposite end of the container, a third row or rows of elements vertically aligned with the first row or rows and a fourth row or rows of elements vertically aligned with the second row or rows. A lashing is secured around the extending end portions of the first and third row or rows and a lashing is secured around the extending end portions of the second and fourth row or rows. The lashings are sufficiently tight to apply a slight pinching of the end portions against the adjacent row or rows to resist relative longitudinal shifting of adjacent rows, but not sufficient to cause any significant deformation of the end portions. 
         [0006]    In a more detailed preferred embodiment of the stack of the present invention, there is added a top row or rows of elements stacked on top of the other rows and generally longitudinally centered with respect to the combined length of the rows of elements therebelow. This top row or rows of elements is included within the lashings that encircle the other rows of the stack and is above the height of the end walls of the container such that the top row or rows will not impact the container end walls upon slight shifting of the top row or rows. 
         [0007]    The elements may be cylindrical with at least two rows of adjacent elements arranged in a nesting pair or pairs and at least one mat of slip resisting material positioned between the rows of the nesting pair or pairs. Spacer bars may be disposed laterally under the lowermost row of the stack and between at least two rows of elements, to provide access for unloading. The intermediate lashings extend through the spaces provided by the spacer bars. 
         [0008]    In broad terms the method of Loading a stack according to the present invention includes loading horizontal rows of elements of substantially equal length in a container having upstanding end walls spaced apart a distance greater than the length of the elements. A first horizontal row or rows of elements is loaded into the container with one end portion at one end thereof adjacent one end wall of the container. A second horizontal row or rows of elements is then loaded into the container with one end portion adjacent the opposite end wall of the container. Means for restraining significant relative lengthwise movement of the rows of elements is then applied. 
         [0009]    In a more detailed preferred embodiment of the method of loading a stack, the loading begins by placing a plurality of spaced laterally extending spacer bars on the container bottom, then placing laterally extending lashings on the container bottom for subsequent lashing together of rows of elements. A first row or rows of elements is loaded on the bottom spacer bars with one end portion adjacent one end wail of the container and the other end spaced from the opposite end wall of the container. A second row or rows of elements is then loaded on top of the first row or rows with end portions adjacent the opposite end wall of the container. A third row or rows of elements is loaded on top of the second row or rows with end portions aligned longitudinally with the end portions of the first row or rows, and a fourth row or rows of elements is loaded on top of the third row or rows with end portions aligned with the end portions of the second row or rows. A lashing is applied around the end portions of the first and third rows and a lashing is applied around the end portions of the second and fourth rows. During this loading, laterally extending, longitudinally spaced, spacer bars and lashings are placed between at least some rows of elements. During sequential loading of rows of elements the previously laid lashings are secured around a plurality of rows of elements including rows above subsequently laid lashings. 
         [0010]    The method of loading may include the further loading of a plurality of upper rows of elements generally centrally disposed between the end walls of the container, with the aforementioned placing of spacer bars and lashings and securing of lashings continuing through the loading of the upper rows of elements. 
         [0011]    In the preferred embodiment the elements are cylindrical, such as pipes, and the method of loading includes laying a plurality of the elements in nested pairs while placing mats of slip resistant material between the rows in the nested pairs. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a side elevational view of a stack of pipes of the preferred embodiment of the present invention shown loaded in a gondola railroad car, with the adjacent side of the car removed for clarity; 
           [0013]      FIGS. 2-16  are perspective views illustrating the sequence of loading of pipes in a gondola railroad car according to the preferred embodiment of the method of the present invention with the end and side walls of the railroad car shown only in dot-dash lines for clarity of illustration of the loaded stack; and 
           [0014]      FIG. 17  is a perspective view of a completed stack of the present invention in a gondola railroad car. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0015]    Following is a detailed description of a stack and method of stacking of a typical embodiment of the present invention incorporating the various features of the invention. 
         [0016]    The stack  20  of elongate elements in the form of cylindrical pipes  22  is illustrated in the drawings loaded in an open top gondola railroad car G that has a bottom B, on which the stack  20  is loaded, side walls  5 , and end walls E and F. Normally, the length of the pipes is less than the interior length between the gondola car&#39;s end walls E and F. Four spaced vertical posts P are secured along each side wall S of the car to retain the stack  20  in place. 
         [0017]    Nine longitudinally spaced bottom spacer bars  24  extend transversely across the gondola car bottom B between the side walls S. A first two nesting rows  26 ,  27  of pipes P are stacked on the bottom spacer bars  24  with end portions  28  at one end adjacent one end wall E and their other ends  29  spaced from the other end wall F of the gondola car G. 
         [0018]    Nine longitudinally spaced spacer bars  30  are disposed laterally on the first two rows  26 ,  27  of pipes  22 . A second two nesting rows  32 ,  33  of pipes P are stacked on the spacer bars  30  with end portions  34  at one end adjacent the other end wall F and their other ends  35  spaced from the one end wall E. In combination, the overall length of the stacked pipes P approximates the interior length of the gondola car G. 
         [0019]    Nine longitudinally spaced spacer bars  36  are disposed laterally on the second two rows  32 .  33  of pipes P. A third two nesting rows  38 ,  39  of pipes P are stacked on the spacer bars  32  aligned lengthwise with the first two rows  26 ,  27  of pipes P, having end portions  40  aligned with the end portions  28  of the first two rows  26 ,  27  of pipes P and other ends  41  aligned with the other ends  29  of the first two rows  26 ,  27 . 
         [0020]    A first end lashing  42  extends laterally under the end portions  28  of the first two rows of pipes  26 ,  27  and over the end portions  40  of the third two rows of pipes  38 ,  39 . This first end lashing  42  is secured by a buckle  44  ( FIG. 8 ) around the end portions  28  and  40  sufficiently tight to apply a slight pinching of the end portions against adjacent rows of pipes to resist relative lengthwise shifting of the adjacent rows of pipes, but not sufficient to cause any significant deformation of the end portions. 
         [0021]    Nine longitudinally spaced spacer bars  45  are disposed laterally on the third two rows  38 ,  39  of pipes. A fourth two nesting rows  46 ,  47  of pipes P are stacked on the spacer bars  36  aligned lengthwise with the second two rows  32 ,  33  of pipes, having end portions  48  aligned with the end portions  34  of the second two rows  32 ,  33  of pipes and other ends  49  aligned with the other ends  41  of the second two rows. 
         [0022]    A second end lashing  50  extends laterally under the end portions  34  of the second two rows  32 ,  33  of pipes P and over the end portions  48  of the fourth two rows  46 ,  47  of pipes. This second end lashing  50  is secured by a buckle  44  ( FIG. 10 ) around the end portions  34  and  48  sufficiently tight to apply a slight pinching of the end portions against adjacent rows of pipes to resist relative lengthwise shifting of the adjacent rows of pipes, but not sufficient to cause any significant deformation of the end portions. 
         [0023]    Nine longitudinally spaced spacer bars  51  are disposed laterally on the fourth two rows  46 ,  47  of pipes. Three nesting pairs of top rows  52 ,  53 ,  55 ,  57 ,  59  and  61  of pipes P are stacked on top of the spacer bars  51  above the other rows and generally longitudinally centered with respect to the combined length of the rows of pipes therebelow. Typically the centered top rows are above the height of the end walls E and F of the gondola car G, where abutting the end walls is not a problem. 
         [0024]    Nine longitudinally spaced spacer bars  54  are disposed between the pairs of top rows  52 ,  53 ,  55 ,  57  and  61 . These top rows are above the height of the end walls E and F of the gondola car G and both ends of the pipes of the top rows are longitudinally spaced from the end walls of the car, so that shifting of the top rows due to abrupt stopping and starting of the car will advantageously not result in the ends of the pipes of the upper rows from extending beyond the end walls of the car. 
         [0025]    Four longitudinally spaced mats  56  of slip resisting material are disposed between the rows of the third nesting pair of rows  38 , between the rows of the fourth nesting pair of rows  46  and between the rows of pipes of each pair of top rows  52 ,  53 ,  55 ,  57  and  61 . These mats  56  assist in resisting longitudinal movement of the adjacent rows upon abrupt stopping and starting of the gondola ear G. 
         [0026]    A plurality of interior lashings combine to form an overlapping network of lashings that confines the pipes in the stacked configuration. These interior lashings extend through the spaces provided by the spacer bars. These interior lashings include a bottom lashing  58  secured around the first, second and third pairs,  26 ,  27 ,  32 ,  33  and  38 ,  39 , of rows of pipes. Three spaced lashings  62  are secured around the third and fourth pairs,  38 ,  39 ,  46 ,  47  rows of pipes and the first pair  52 ,  53  of top rows of pipes. Three spaced lashings  64  are secured around the fourth pair  46 ,  47  and the first pair  52 ,  53  of top rows. Three spaced lashings  66  are secured around the fourth pair  46 ,  47  and the first two pairs  52 ,  53 ,  55 ,  57  of top rows of pipes. Three spaced lashings  68  are secured around the lower two pairs  52 ,  53 ,  55 ,  57  of top rows of pipes. Three spaced lashings are secured around the top two pairs  55 ,  57 ,  59 ,  61  of top rows of pipes. Each of these interior lashings is secured by a buckle  44 . 
         [0027]    With this arrangement of interior lashings, at least one of the interior lashings extends under the lowermost row of pipes, at least one other interior lashing extends over the top row of pipes and under at least one row of pipes therebelow, and other interior lashings are each secured around a plurality of rows of pipes that includes one row that is also secured within at least one of the other interior lashings. This creates a strong confinement network of lashings to hold the pipes in the stacked configuration. While particular lashing arrangements are disclosed, variations may be utilized as well, provided there is a sufficient number of lashings in overlapping relation to tie the pipes together in a firm stack. 
         [0028]    To prevent spreading apart laterally of the vertical posts P and to facilitate retention of the stack  20  in place, the posts are arranged in lateral pairs with each pair having a post on each opposite side of the gondola car G, and cross-retaining lashings  74  are looped around each pair of posts across rows of pipes with the ends of the lashings secured by buckles  44 . These cross-retaining lashings  74  are disposed above each pair of top rows of pipes and between the nested pipes of the top pair of the top rows of pipes. 
         [0029]    In a typical commercial application of the preferred embodiment of the present invention, the pipe stack  20  is loaded in a gondola freight car G that extends  52  feet between the end walls E and F, with side walls S that extend upward 5 feet above the bottom B of the car G. The vertical posts P are wooden 4×4s. The pipes  22  are, for example, steel pipes of 3 to 11 inches in diameter, commonly 5½ inches, and 42 to 48 inches in length. Commonly, there are 40 or more pipes  22  in a typical stack  20  and the stack is typically about 9 feet high. Typically, the section of pipes that have pipes with end portions extending beyond the ends of other pipes amounts to about 60% of the height of the stack, and the top rows of the stack, amount to about 40% of the height of the stack. The lashings may be woven polyester fabric 1⅝ inches thick, such as sold by Carolina Strapping and Buckles Company of Gastonia, N.C. The slip-resistant mats  56  are made of rubber, or similar material, and are typically ⅛ of an inch thick and 18 inches wide. The spacer bars  30 ,  36 ,  45 ,  51  and  54  are typically wooden 2×4s. 
         [0030]    The method of the preferred embodiment of the present invention begins ( FIG. 2 ) with attaching the vertical posts P to the side walls S of a gondola railroad car G. Then nine longitudinally spaced bottom spacer bars  24  are placed transversely on the bottom B of the car G. A bottom interior lashing  58  is placed across the bottom B of the car G in the general area of the middle of the car G. This bottom interior lashing  58  has ends draped over the side walls S of the car G. Also, first and second end lashings  42  and  50  are placed across the bottom B near the ends of the car G with their ends draped over the side walls S. 
         [0031]    The rows of the first two rows  26 ,  27  of pipes are individually laid on the bottom spacer bars  24  with end portions  28  abutting one end wall E of the car G and the other ends  29  spaced from the other end wail F of the car G ( FIGS. 3 and 4 ). Typically the rows of pipes are loaded using a magnetic loader or a fork lift. 
         [0032]    As illustrated in  FIG. 4 , nine spaced spacer bars  30  are placed across the first two rows  26 ,  27  of pipes and three spaced interior lashings  60  are placed across the first two rows  26 ,  27  of pipes and draped over the side walls S of the car G. 
         [0033]    As illustrated in  FIGS. 5 and 6 , the pipes of the second two rows  32 ,  33  of pipes are individually laid on top of the spacer bars  30  with end portions  34  abutting the other end wall F of the car G and their other ends  32  spaced from the one end wall E of the car G. Nine spaced spacer bars  36  and four spaced interior lashings  62  are then placed across the top of the second two rows  32 ,  33  of pipes, with ends of the lashings draped over the side walls S of the car G. 
         [0034]    As illustrated in  FIG. 7 , the first row  38  of the third two rows  38 ,  39  of pipes is laid on top of the spacer bars  32  that are on top of the second two rows  32 ,  33  of pipes with end portions  40  abutting the one end wail E of the car G. Four longitudinally spaced slip-resisting mats  56  are placed on top of the first row  38  of the third two rows  38 ,  39  of pipes. As illustrated in  FIG. 8 , the second row  39  of pipes of the third two rows are placed on the mats  56  in nesting relation to the first row  38 . Four spaced lashings  64  and nine spaced spacer bars  45  are placed on top of the third two rows  38 ,  39  of pipes. The first end lashing  42  is wrapped around the end portions  28  and  40  of the first and third two rows of pipes and secured by a buckle  44  sufficiently tight to apply a pinching pressure to the intermediate second two rows  32 ,  33  of pipes to resist shifting thereof, but with the pressure being insufficient to cause deformation or bending of the first and third two rows  26 ,  27 ,  38 ,  39  of pipes. The previously laid interior lashings  58  and  60  are secured across the top of the third two rows  38 ,  39  of pipes. 
         [0035]    As illustrated in  FIG. 9 , the first row  46  of the fourth two rows  46 ,  47  of pipes is laid on top of the spacer bars  45  on top of the third two rows  38 ,  39  of pipes with end portions  46  abutting the other end F of the car G. Four longitudinally spaced slip-resisting mats  56  are placed on the first row  46  of the fourth two rows  46 ,  47  of pipes. As illustrated in  FIG. 10 , the second row  47  of pipes of the fourth two rows  46 ,  47  are placed on the mats  56  in nesting relation to the first row  46 . Three spaced lashings  66  and nine spaced spacer bars  45  are placed on top of the fourth two rows  46 ,  47  of pipes. The second end lashing  50  is wrapped around the end portions  34 ,  48  of the second and third two rows  46 ,  47  of pipes and secured by a buckle  44  sufficiently tight to apply a pinching pressure to the intermediate third two rows  38 ,  39  of pipes to resist shifting thereof, but with the pressure being insufficient to cause deformation or bending of the second and fourth rows  32 ,  33 ,  46 ,  47  of pipes. 
         [0036]    A first row  53  of a first pair  53 ,  55  of nesting top rows is laid on top of the top row  47  of the fourth pair of pipes and is centrally disposed between the ends E and F of the car G. Four spaced mats  56  are placed on the first row  53  ( FIG. 11 ). The second row  55  of the first pair of top rows  53 ,  55  is then placed in nesting relation on the first row  53  with the mats  56  therebetween ( FIG. 12 ). The previously laid unsecured lashings  62  and  66  are wrapped over the first pair of top rows and secured by buckles  44 . Cross-retaining lashings  74  are wrapped around each pair of vertical posts P and secured by buckles  44 . 
         [0037]    A first row  57  of a second pair of top rows  57 ,  59  is placed on the spacer bars  54  in alignment with the first pair  53 ,  55  of the top rows and four spaced mats  56  are placed on this first row ( FIG. 13 ). 
         [0038]    The second row  59  of the second pair  57 ,  59  of top rows is placed on the mats  56  in nesting relation to the first row of the second pair and the previously laid unsecured lashings  63 ,  64 ,  68  are wrapped over the second pair of top rows and secured by buckles  44 . Nine spaced spacer bars  53  and three spaced lashings  70  are laid on top of the second pair of the top rows, and cross-retaining lashings  74  are wrapped around each pair of vertical posts P and secured by buckles  44  ( FIG. 14 ). 
         [0039]    A first row  59  of a top pair  59 ,  61  of top rows is placed on the spacer bars  54  aligned with the other rows of the top rows and four spaced mats  56  are placed on this first row of the top pair of top rows. Cross-retaining lashings  74  are wrapped around each pair of vertical posts P and are secured by buckles ( FIG. 15 ). 
         [0040]    The second row, or top row,  61  of the top pair of rows is placed on the mats  56  in nesting relation to the first row of the top pair of rows and the previously laid unsecured lashings  66 ,  68 ,  70  are wrapped over the top row and secured by buckles  44 . Cross-retaining lashings  74  are wrapped around each pair of vertical posts P and are secured by buckles  44  ( FIG. 16 ) to complete the loading of the stack  20 . 
         [0041]    The spacer bars provide spaces between the pipes that are above and below each spacer bar, for ease of access in unloading of the stack. However, spacer bars do not provide a significant advantage with respect to shifting of the pipes and their use is optional. 
         [0042]    The above description recites particular numbers of spacer bars,  30 ,  36  and  54 , and mats  56 , which numbers are optional. Preferably, but not necessarily, there are at least four spacer bars per row, and at least two mats per row, and use of mats between rows of pipes below the height of the end wails of the gondola car is optional. 
         [0043]    In view of the aforesaid written description of the present invention, it will be readily understood by those skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications, and equivalent