[Federal Register Volume 68, Number 226 (Monday, November 24, 2003)]
[Notices]
[Pages 65982-65983]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-29338]


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DEPARTMENT OF TRANSPORTATION

Federal Railroad Administration


Safety Advisory 2003-03

AGENCY: Federal Railroad Administration (FRA), DOT.

ACTION: Notice of safety advisory.

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SUMMARY: FRA is issuing Safety Advisory 2003-03, which provides 
additional information on the potential catastrophic failure of 100-ton 
truck bolsters manufactured by National Castings of Mexico's (NCM) 
Sahagun, Mexico facility with Association of America Railroads (AAR) 
Identification Numbers B-2410 and B-2409 and National Patterns 52122 
and 52202, respectively, used in 263,000 pound and 286,000 pound gross 
rail load freight cars. These two bolster patterns were manufactured by 
NCM from 1995 through 1998 and were installed on 29,186 U.S. freight 
cars of various type construction. Additionally, an overview of the 
railroad industry's AAR Safety Action Plan for appropriate handling and 
disposition of these cars is contained in this advisory.

FOR FURTHER INFORMATION CONTACT: Ronald Newman, Staff Director, Motive 
Power and Equipment Division (RRS-14), FRA Office of Safety Assurance 
and Compliance, 1120 Vermont Avenue, NW., Washington, DC 20590, 
telephone: (202) 493-6241 of Thomas Herrmann, Staff Attorney, FRA 
Office of Chief Counsel, 1120 Vermont Avenue, NW., Washington, DC 
20590, telephone: (202) 493-6036.

SUPPLEMENTARY INFORMATION: On December 30, 2002, FRA issued Safety 
Advisory 2002-03 which identified a problem with National Castings of 
Mexico (NCM) bolsters bearing AAR identification B-2410, and 
National Pattern 52122 used in 263,000 and 286,000 pound gross rail 
load freight cars. In that advisory, FRA referenced AAR Maintenance 
Advisory MA-81 and AAR Early Warning Letters EW-5191, EW-5191-S1, and 
EW-5191-S2 that indicated there were as many as 15,000 freight cars in 
revenue service, which may be equipped with the NCM bolsters. Since 
publication of FRA Safety Advisory 2002-03, FRA has been made aware of 
another series of bolsters, AAR Identification  B-2409 and 
National Pattern 52202, which pose a similar potential safety hazard. 
The NCM bolsters with pattern 52202 have been referenced in AAR Early 
Warning Letters EW-5194, EW-5195, EW-5196, and EW-5197. The total 
estimated population of defective truck bolsters from both NCM patterns 
is 58,373 bolsters. This large number of truck bolsters represents a 
fleet of roughly 29,186 freight cars, which may be equipped with the 
defective NCM bolsters. Extensive fatigue testing of both types of 
bolsters (both patterns 52122 and 52202) at the AAR Transportation Test 
Center in Pueblo, CO and two other laboratories confirmed a tendency of 
these bolsters to develop internal cracking (design flaw) which can 
lead to sudden and catastrophic failure. The fatigue testing indicated 
that the action plan, as outlined by the AAR and contained herein, 
would be an appropriate industry response for dealing with these 
defective bolsters.
    During the week of March 10, 2003, the AAR tendered its Industry 
Safety Action Plan (the Plan), to FRA for the handling of potentially 
defective NCM bolsters. In this plan, a unique risk analysis was 
developed by the AAR to prioritize the removal of the bolsters (from 
tank cars and other high risk commodity shipments) without causing 
industry operating impacts due to unavailable and/or extremely delayed 
equipment for loading. AAR's risk assessment was built upon hazardous 
material commodity classifications, mileage (utilization) factors, 
loading/impact factors, to arrive at a composite risk rating. AAR also 
considered the original equipment manufacturer (OEM), supply/demand and 
existing inventory of replacement bolsters when determining the degree 
of risk to be assigned to each car type identified as having been 
equipped with the defective bolsters.
    The Plan approved and implemented by AAR's Technical Services 
Working Committee (TSWC) provided the following proactive safety 
measures:
    1. Tank car owners must complete 20% of their HAZMAT cars (complete 
bolster replacements) no later than May 31, 2003, and a minimum of 20% 
per month, thereafter, with 100% replacement no later than September 
30, 2003 (Group I, HAZMAT cars).
    2. Mill gondola and coal cars (subject to vertical loading impacts) 
must have bolsters either replaced or requalified (via radiographic 
inspection) no later than December 31, 2003 (Group II cars).
    3. All other cars must either have bolsters replaced or requalified 
(via radiographic inspection) no later than April 1, 2004 (Group III 
and Category III, Tank cars, non-HAZMAT service).
    FRA recognizes that some of the dates in the AAR industry action 
plan have not been met for a variety of reasons, primarily the result 
of not having a sufficient quantity of replacement bolsters. AAR, the 
railroads and car owners have taken additional measures to ensure 
safety based on AAR's waiver review, cars held out of service and 
special inspection procedures. Since initiation of the Industry Safety 
Action Plan, there have been no reported in-service bolster failures.
    It should be noted that FRA Hazardous Materials Regulations (HMR), 
contained in 49 CFR parts 171-180, set forth the requirements for the 
safe transportation of hazardous materials in commerce by railcar, 
aircraft, vessel, and motor vehicle. The HMR prescribe requirements for 
classification, packaging, hazard communication, shipping papers, 
incident reporting, handling, loading, unloading, segregation, and 
movement of hazardous materials. FRA understands that there may be as 
many as 3,300 tank cars originally equipped with either the NCM 
bolsters in pattern(s) 52122 or 52202, some of

[[Page 65983]]

which may be in assigned hazardous materials shipments.
    Recommended Action: In recognition of the need to assure safety, 
FRA recommends that railroads, manufacturers, and car owners make every 
attempt to adhere to the Industry Safety Action Plan developed by AAR 
and expedite wherever possible the handling of potentially defective 
NCM bolsters. FRA realizes that the industry has been delayed to some 
extent in meeting the time schedules detailed in the Safety Action Plan 
due to the short supply of replacement bolsters and the desire to 
minimize operating impacts. With this in mind, FRA expects owners of 
hazardous materials tank cars equipped with these defective bolsters to 
have the cars shopped once the cars become empty and NOT RELOAD until 
defective bolsters have been removed and once defective bolsters have 
been removed to so notify the AAR.
    Failure of the rail industry to voluntarily take action consistent 
with the AAR Industry Safety Action Plan may result in FRA pursuing 
other corrective measures to enforce public safety under its rail 
safety authority. FRA may modify this Safety Advisory 2003-03, issue 
additional safety advisories, or take other appropriate action 
necessary to ensure the highest level of safety on the nation's 
railroads.

    Issued in Washington, DC, on November 18, 2003.
George A. Gavalla,
Associate Administrator for Safety.
[FR Doc. 03-29338 Filed 11-21-03; 8:45 am]
BILLING CODE 4910-06-P