INSPECTION BULLETIN

Side Sill ClosureInspection and Repair

This inspection Bulletin provides details for the inspection and modification of side sill closure plates onACF built Center Flow® covered hopper cars. The closure plate may be referred to as the pistol plate, or hairpin closure.

The side sill closure plate was utilized from 1978 – 2005. The areas shown below should be inspected fordiscontinuities in the form of cracks emanating from the welds at the inboard end of the closure plateattachment to the side sheet and at the bolster bottom cover attachment to the side sill. In all cases,replacement with a new closure plate is recommended at all four corners.

Built Years: 1978–1981 Built Years: 1981–2005

Enlarged view

1

SIDE SHEET

SIDE SILL

SHEAR PLATE

UPPER BOLSTER WEB

LOWER BOLSTER WEB

BOLSTER BOTTOM COVER

ORIGINAL "HAIRPIN"SIDE SILL CLOSURE

AREA “A”

AREA “B”

Inspection & Repair of Inboard Weld Termination

Inspection:

• Remove all dirt and debris from Areas “A” and “B” by wire brushing.• Dye-penetrate inspect these areas.• If no cracking is found proceed with replacement of the side sill closure plate (recommended), or return

the car to service. If the car is returned to service without replacement of the closure plate a plan shouldbe implemented to inspect this area on a routine basis.

Cracks emanating from the welds can propagate up into the side sheet and down to the inside radius ofthe side sill and outward along the bottom of the side sill.

Critical Note: If any of the following special conditions are observed it will be necessary to replacea section of the side sill. See “Side Sill Section Replacement.”

• A crack that splits and branches in multiple directions• Two or more cracks within 3" of one another• A crack that is open 1/32" or greater• A crack that propagates into the outside radius of the side sill, see below.

2

OUTSIDE RADIUS

AREA “A”

AREA “B”

Side Sill Closure Plate – Removal

• Remove the side sill closure plate by air arc or burning.

• Remove a section of the bolster bottom cover and bolster web.

12.5”

3

SHEAR PLATE

LOWER BODY BOLSTER

SIDE SILL

REMOVE LOWER BOLSTER WEBAND BOTTOM COVER PLATE

REMOVE BOLSTERBOTTOM COVER PLATE

1/2" NO WELD ZONE

3" REF

SIDE SHEET

SIDE SILL

SHEAR PLATE

UPPER BOLSTER WEB

LOWER BOLSTER WEB

BOLSTER BOTTOM COVER

ORIGINAL "HAIRPIN"SIDE SILL CLOSURE

Side Sheet Inspection & Repair

• With the closure plate removed, dye-penetrate inspect the side sheet, and the inboard and underside ofthe side sill for cracks.

• Any surface that is gouged due to removal of the closure plate, 1/16" deep or greater, will require repair.Use E7018 electrode or equivalent wire and grind smooth.

• All grinding is to be in the horizontal direction, longitudinal to the car body.• Repair side sheet cracks, see highlighted section below, by gouging out the crack and welding.

4

SIDE SHEET

VIEW WITH CLOSURE PLATE REMOVED

Side Sill Inspection & Repair Procedures

Inspection

• With the closure plate removed, dye-penetrate inspect area “A.”

Repair

• Side sill cracks must be repaired from both sides.• Access to the interior of the side sill is gained by cutting a window, 8" vertical x 12" horizontal, in the

outside vertical flat of the sill. Radius the corners to 2" minimum. Save the cutout scrape to seal theaccess window when the repair is completed.

• The outboard edge of the opening must be 1-1/2" from the inboard edge of the shear plate.• Beginning inside the sill, remove the crack by air arcing the affected area plus 1/2" beyond the crack

length to a depth of 1/4". Prepare the area for welding.• Weld the area using E7018 electrodes or equivalent wire. Weld first pass stringer and weave the

remaining passes.• Prepare the outside surface with air arc to a depth that will ensure a 100% weld penetration in weld.

Prepare the area for welding.• Weld the area using E7018 electrodes or equivalent wire. Weld first pass stringer and weave the

remaining passes.• Close the access window by preparing the edges of the sill opening and the saved panel.• Apply 1/8" x 2" wide back-up strips inside window opening.• Replace the panel section and weld with E7018 electrodes or equivalent wire ensuring

100% penetration.

5

SHEAR PLATE IN BOARD EDGE SIDE SILL

LOWER BODY BOLSTER1/2" NO WELD ZONE

8" X 12" ACCESS WINDOW}

Side Sill Section Replacement

From the Critical Note on page 2, certain conditions necessitate replacing a section of the side sill. This areais defined as the “Critical Repair Area,” and extends from the centerline of the adjacent compartment toa minimum of 8" beyond the centerline of the body bolster, or if desired, to the end of the car.

Conditions requiring replacement of the side sill section:

• A crack that splits and branches in multiple directions• Two or more cracks within 3" of one another• A crack that is open 1/32" or greater• A crack that propagates into the outside radius of the side sill.

Procedure

• Remove the Critical Repair Area sill section using air arc and exercising caution to avoid damage to thehorizontal shear plate and side sheets.

• A tie plate connecting the bottom of the side sill to the compartment slope sheet is located at thecenterline of each compartment. Split the tie plate in the middle and replace the side sill section byfitting a 1/8" x 2" back-up strip and butt welding the two sections together using E7018 electrode orequivalent wire and ensuring 100% penetration.

• Relocate the roping staple 12" outboard of the body bolster web.• Apply the previously removed section of tie plate and butt weld the two sections together.

6

Side Sill Closure Plate – Replacement

CRITICAL NOTE: All four corners of the car must be modified when applying the new design side sillclosure plate.

• Repair all nicks, gouges, and undercuts, 1/16" deep or greater, in the side sill using E7018 electrode orequivalent wire and grind smooth. All grinding to be horizontal, or longitudinal to the car body.

• Tack weld new side sill closure plate into position, detail E. The opening in the upper bolster web mayneed to be enlarged to accommodate new closure plate.

• Weld closure plate to the shear plate, side sill and side sheet per section D-D. Note – The no weld zonesare critical and must not be violated.

• Caulk the inboard no weld zones.• Touch up repairs with matching paint.

7

1.00NO WELD ZONE

WELD MUST BE CONTINUOUSBETWEEN THESE POINTS.NO UNFILLED CRATERS.

1/4

5/16 47.2

6.75

E

SECTION D-D

CLOSURE TO SIDE SHEET ANDUPPER BOLSTER WEB IN FRONTOF WEB

CLOSURE TO SIDESHEET AND UPPERBOLSTER WEB

5/16

3

4

.37(.37)

1/4

4

45˚0

CLOSURE TO SHEAR PLATEBEHIND UPPER BOLSTER WEB

CLOSURE TO SIDE SHEETAND UPPER BOLSTER WEBBEHIND WEB

.37(.37)

1/4

5/16

1.00NO WELD ZONE

8.8

45˚

28

0

NO WELD ZONETO BE CAULKED

D

D

DETAIL E

1.00NO WELD ZONE

1.00 CLEARANCE

1.00NO WELD ZONE

3

1Side Sill Reinforcements – 3N713200, 4 required

2Side Sill Closure Plate – 4W709100, 2 required

3Side Sill Closure Plate – 4W709101, 2 required

A

100 Clark Street, St. Charles, Missouri 63301

AMERICAN RAILCAR INDUSTRIES, INC.

636.940.6020 • FAX: 636.940.6100www.americanrailcar.com • sales@americanrailcar.com 8

March 2010

SIDE SILL REINFORCEMENT3N713200

.50 FROM TANGENT

END OF CAR

REINFORCEMENT PLATETO BOTTOM OFSIDE SILL

30.00 FROMEND OFSIDE SILL

REINFORCEMENT PLATETO BOTTOM OFSIDE SILL

NO WELDZONE 2 PL

NOTE:TERMINATE THE LONGITUDINAL WELD NO FURTHER THAN THE 45 DEG ANGLEBEYOND THE END TANGENT POINTS AS SHOWN IN DETAIL “A.” DO NOTWELD THE TRANSVERSE ENDS OF THE REINFORCEMENT.

90˚

5/16 114.13

A

DETAIL A

114.75

45˚4 PL

5/16

SIDE SILL CLOSURE — 2 4W709100 (BL & AR)

3 4W709101 (BL & AL)

1

ARI makes no representations or warranty, express or implied, with respect to the contents herein, and assumesno contractual or other liability with respect to any use which the customer may make of this Information Bulletin.