Flat Rack Loading Guidelines

August 2010

Horizon Lines Guidelines for Loading Flat Racks

The following illustrated procedures and text provide
standard guidelines for the most common types of
cargo transported by ship on Flat Racks. The purpose
of this program is to facilitate loading and securing
while assuring that the cargo will arrive at destination
in the condition in which it was received at origin.
Each trade lane/tariff specifies what is overdimensional cargo. Customers should check the
tariff to see if their cargo falls under this classification.
For unusual loads or clarification of instructions set forth,
contact the Operations Supervisor at the terminal
nearest you.
OVERLENGTH LOADS Any load over 40 in length is
considered over length. If the load does not exceed
44, then center the load. If the load exceeds 44,
please contact the Operations Supervisor, prior to
loading, for further instructions.
OVERWIDTH LOADS Any load over 8 in width is
considered over width. For loading instructions,
please contact the Operations Supervisor prior to
loading.
NON-POST FLAT RACKS In order to allow access to the
lifting points on the end of the flat rack, cargo should
be loaded with 18 to 24 free space on each end of
flat racks which dont have corner posts. Otherwise
the load cannot be picked by the crane at the dock or
unhooked once aboard, if stowed below deck.

INTENDED USE OF THIS PROGRAM:

The steps and comments on each slide are presented in an
order designed to ensure a properly secured load,
which will meet the challenges of ocean transit, while
saving time and expense in loading and securing
typical cargo.
1.

LOOK AT THE COMPLETED LOAD FOR THE COMMODITY

TO BE SHIPPED. (All steps on slide together)

2.

CLICK MOUSE, HIT SPACEBAR, OR PUSH PAGE

DOWN BUTTON TO STEP THROUGH SLIDE. (Step
number is located at top, left-hand corner.)

3.

READ THROUGH EACH STEP CAREFULLY AND STUDY

FOR RECOMMENDED SEQUENCING OF STEPS.

4.

RETURN TO THE FIRST STEP BY SELECTING THE

PAGE UP BUTTON AND BEGIN LOADING WHILE
REFERENCING EACH STEP, IN SEQUENCE.

5.

THIS PROGRAM IS A GUIDELINE TO BE USED IN

CONJUNCTION WITH EXPERIENCE AND GOOD
JUDGEMENT. IF YOU HAVE QUESTIONS, CONTACT
THE OPERATIONS MANAGER FOR ASSISTANCE AND
CLARIFICATION.

General Safety Guidelines

The cargos weight (not necessarily the cargo itself) should be centered on the flat.
The cargos weight needs to be distributed over the length of the flat such that the load per linear foot
does not exceed 2500 lb.
The number of lashings used to secure the load must be based on the weight of the load being secured.
These securing devices must have a maximum securing load equal to or greater than the mass
(weight) of the cargo on each transverse side. They should be distributed equally around the load.
Maximum Securing Load or MSL is normally expressed in kilonewtons and is the greatest permissible
force which can be applied to a load securing element or device. MSL is determined based on the
breaking strength of the material in question based on the following table. If the BS or MSL are not
known then the working load limit (WLL) or Safe Working Load (SWL) may be utilized for MSL.
Material
MSL
Shackles, rings, deck eyes,
50% of breaking strength
or turnbuckles of mild steel
Fiber ropes
33% of breaking strength
Web lashing
70% of breaking strength
Wire rope (single use)
80% of breaking strength
Wire rope (re-useable)
30% of breaking strength
Steel band (single use)
70% of breaking strength
Chains
50% of breaking strength
Lumber
0.3 kN per cm normal to the grain
Cargo should be directly lashed from fixed lashing points on the cargo to the flat rack securing points. If
the cargo does not have fixed lashing points (crates, pipes, etc) then half-loop lashings may be
utilized to secure the cargo to the flat rack. Other methods may be utilized which prevent sliding.

General Safety Guidelines (continued)

Chains and Binders

Chains should be Binding Chain Grade 70 (minimum 3/8 link; 6,600 lb load limit) or stronger.

Chains must be free of cracks, bent or twisted links, gouges or pits and knots.

Chain must be secured back into chain and not to the flat rack.

Chain must not be secured to the yellow rub rail on the flat rack.

Binders should have a safe working load of at least 5,400 lb.

Binders must have two grab hooks compatible with the size chain being used.

Binders are not to be welded to the chain.

Binders should be located up on the load in such a way that they are not to the outside of
the flat rack metal.

Binders should be secured in the locked position using tie wraps or wire.
Web/Nylon Straps/Cord Lash

Straps should be rated to a minimum of 22 kiloNewtons or 4500 lb maximum securing load (MSL).

Web/Nylon Straps and Cord Lash shall utilize the proper tensioning equipment recommended by the
manufacturer.

Straps must be free of cuts and broken or loose stitching.

Straps that are frayed should not be used.

Straps should be attached to the approved lashing points on the flat rack.

Chaffing material should be utilized around sharp edges.

Winches

Winches, ratchet eyes, connection chains, etc. must have a breaking strength the breaking
strength of the straps.

Winches must be free of sharp edges or defects that could damage the webbing.

General Safety Guidelines (continued)

Steel Banding

Steel bands must be at least 1 inches wide, 0.031 gauge.

Steel banding should be secured using double clips with double crimps.

Chaffing material should be utilized around sharp edges

Blocking and Bracing

Lumber Blocks should be made of hardwood and should be free of defects, knots & cracks.

Blocking should be as wide as they are high.

If the blocking is not of like dimensions, the wider dimension must be horizontal. If the blocking is
6X 8 the 8 should be laid flat against the deck.

Blocking should not be nailed together to make 4 x 4, 6 x6, etc. Use the appropriate blocking for
the load.
Wire

Wire utilized in lashings shall have a minimum diameter of 1/2

A minimum of four (4) wire clips shall be utilized to complete the eye at end of wire.

The grip end of the clip shall be placed on the live side (tensioned side) of the wire.

Chaffing material/Softeners shall be utilized around sharp edges and to protect cargo.
Turnbuckles/Shackles

Use only forged eye to eye Turnbuckles

Shackles and Turnbuckles shall have a minimum throat thickness of .

Shackles and Turnbuckles shall have a minimum of 11,000 LB or 49 kN Maximum Securing Load
(MSL)

General Safety Guidelines (continued)

Chaffing material/Softeners

Used rubber hose, cardboard, plastic and carpet can be used as chaffing material. When cardboard
is used be mindful that it can become wet and decompose while on a ship at sea.

Chaffing material should be used between steel banding, chain, wire rope and other similar types of
securement and points of contact with the cargo and flat to protect the cargo and the straps.

Chaffing material should be secured such that load shifts during transport will not cause
displacement of the softener and loss of protection for the load.
Steel & Pipe

Do not load steel on steel (this includes steel cargo against steel deck areas of the flat).

The widest dimension of the load should be at the bottom.

Chains are required for use in securing all steel beams, steel plates, and metal igots.

Chaffing material should be used under lashings to protect steel that is susceptible to damage and
protect the lashings around sharp edges.

Steel beams should be blocked in the web and wedged between flanges to prevent movement
between the beams.

Unsecured items inside of pipe or intermixed with steel beams or other structural steel are not
allowed.

Belly Banding should be used at least every 10 feet in length; at least 2 belly straps should be used
on the shortest piece in the stack.

Product being belly wrapped should be stacked tightly together to keep the load from shifting side
to side and loosening the belly wrap.

Rebar can be secured using web straps provided belly banding is done with chain.

Transverse Bearers should be utilized to spread the load to the side rails of the flat rack

The ends of the steel and pipe should be blocked to the end walls/corner posts of the flat rack.

General Safety Guidelines (continued)

Dunnage/Transverse Bearers

If Multiple pieces of dunnage are required they must be nailed together.

Pallets should not be used as dunnage.

Transverse Bearers should be utilized to spread the cargo weight to the side rails of the flat rack.

WARNING: Cargo which sits directly on the lumber floor of the flat rack without cross beams to the
side rails may damage the flat rack. The strength of the flat rack is concentrated in the side rails.

General Safety Guidelines (continued)

Half-Loop Lashings

Half Loop Lashings are used to secure cargo which has no fixed securing points

Half Loop Lashings should not be used on over-wide cargo

Half Loop Lashings may be used on lumber cases, steel beams, pipe, and steel sheets

A Half Loop Lashing must start and end on the same side of the flat rack.

To install a half loop lashing, the lashing material is fed over the top of the cargo, down the opposite
side and then under the cargo (between cargo and floor of flat rack) and then secured on the same
side the lashing started on.

Each Half Loop Lashing on one side must be paired with a second half loop lashing on the opposite
side.
Half Loop Lashing Example

Menu
Click the type of loading scenario to view:
Lumber/Plywood page 11
Sheetrock page 12
Palletized Drums & Crates page 13
Steel Beams page 14
Pipe/Drillstem page 15
Plastic Pipe page 16
Rolls of Chain Link Fencing page 17
Light Trucks page 18
Large Trucks page 19
Heavy Equipment page 20
Highway Trailers page 21

10

Menu Cont
Click the type of loading scenario to view:

Spools page 22
Cement Man Holes page 23

11

Lumber/Plywood

1.

Position transverse
lumber bearers.

2.

Center Load on Flat.

Use dunnage
between stacks fore
and aft.

3.

Place 2 belly bands

around each bundle
using protectors
4.

Install Transverse
Lashings to
secure cargo to
flat using 2
lashings per
bundle.

5.

Install blocking
from ends of
cargo to end wall/
corner posts if
necessary.

Youre done!
Belly bands are
indicated by an
angled line.
Color Code:
Brown
Bearers/Dunnage
Blue

Belly Bands

Green Half Loop Lashing

Lt. Blue

Corner

12

Sheetrock

1.

Position transverse
lumber bearers.

2.

Center Load on Flat.

Use dunnage between
stacks fore and aft.

3.

Secure bundles by
using edge protectors
and 2 belly bands on
each bundle.
4.

Poly wrap load

5.

Install Transverse
Lashings to
secure cargo to
flat using 2
lashings per
bundle.

6.

Install blocking
from ends of
cargo to end wall/
corner posts if
necessary.

Youre done!
Color Code:
Brown
Bearers/Dunnage
Blue

Belly Bands

Green Half Loop Lashing

Lt. Blue
Protectors

Corner

13

Palletized Drums and Crates

NOTE: The preferred stowage of drums and pallets is in a standard closed container. Securing
a large amount of drums/pallets on a flat rack is a difficult and time consuming operation.

1.

Center load on
platform and nest
pallets tightly to one
another. Drums to be
banded to each other
on each pallet.

2.

Place 2 belly bands

around each stack.
3.

Install Transverse
Lashings to
secure cargo to
flat using 2 loops
per bundle.

4.

Install blocking
from ends of
cargo to end wall/
corner posts if
necessary.

Youre done!
Color Code:
Brown
Blue

Bearers/Dunnage
Belly Bands

Green Half Loop Lashings

14

Steel Beams

1.
2.
3.

4.

5.
Center load. If over length exceeds 4 feet, confirm with operations how much overhang on each side.
6.

Note:
Be aware of gross weight while loading.

Position transverse
lumber bearers
Place dunnage
between beams.
Belly lash first level
using corner
protectors as
needed. Repeat 1,
2, and 3 for each
successive level.
Belly Lash each
stack with 2 Chains
per stack. Use
corner protectors
as needed.
Install Transverse
Lashings to secure
cargo to flat using 2
loops per bundle.
Install blocking
from ends of cargo
to end wall/ corner
posts if necessary.
If cargo is
overlength as
pictured cargo nets
may be required to
secure ends.

Color Code:
Brown

Bearers/Dunnage

Blue

Belly Bands by level

Red

Belly Bands entire stack

Green Half Loop Lashings

15

Pipe/Drill Stem
1.

Position transverse
lumber bearers.

2.

Center load on flat,

building one layer at a
time. Use dunnage
between each layer.
3.

Belly lash each

layer before
loading the next
layer.

4.

Belly Lash entire

load.

5.

Install Transverse
Lashings to secure
cargo to flat using 2
loops per bundle.

6.

Install blocking from

ends of cargo to end
wall/ corner posts if
necessary.

Youre done!

Color Code:
Brown

Bearers/Dunnage

Blue

Belly Banding each level

Red

Belly Banding entire stack

16

Plastic Pipe

1.

2.

Load plastic pipe on stickers setting dunnage between each layer.

Lay lashings in
12 lengths
across flat rack at
point where
setting each
transverse
bearer. Set
bearers on each
lashing.
Attach additional
banding to short
sections under
bearers and belly
band the load.

5.

Install Transverse
Lashings to
secure cargo to
flat using 2 loops
per bundle.

6.

Install blocking
from ends of cargo
to end wall/ corner
posts if necessary.

Youre done!
Color Code:
Brown
Blue

Bearers/Dunnage
Belly Bands

Green Half Loop Lashings

17

Rolls of Chain Link Fencing

1.

Place transverse
bearers at corner
posts. Load wire
rolls on platform.

2.

Place 2x4
boards on end of
rolls.

3.

Run lashings
across ends of
flat rack over the
2 x 4 lumber and
tighten until
secure
Belly Band each
roll to adjacent
roll to unitize
load.
Install Transverse
Lashings to
secure cargo to
flat passing
through top roll.

4.

5.

Youre done!
Color Code:
Brown
Red

Bearers/Dunnage
Half Loop Lashings

18

Light Trucks
Click for next step
1.

Center load on flat.

2.

Install chocks and

nail in place

3.

Secure using at least

2 lashings on each
side.

4.

Cross lash to front

and rear of each axle.

Youre done!
Note: When using chains
be certain chains that are
wrapped around axles do
not contact brake lines
Use manufactures tie
down points wherever
possible.

Color Code:
Brown

Chocks

Blue

Nails

Red

Direct Lashings

19

Heavy Trucks
Click for next step
1.

Center load on flat.

2.

Install chocks and

nail in place

3.

Secure using at least

4 lashings on each
side.

4.

Cross lash to front

and rear of each axle.

Youre done!
Note: When using chains
be certain chains that are
wrapped around axles do
not contact brake lines
Use manufactures tie
down points wherever
possible.

Color Code:
Brown

Chocks

Blue

Nails

Red

Direct Lashings

20

Heavy Equipment
1.

Center weight of load

on flat. Lower
bucket. Secure
steering. Use Heavy
Lumber Bearers
under wheels/tracks
to distribute load to
side rails if required

2.

Block all tires on

both sides and nail in
place.

3.

Secure with a
minimum of 4
lashings on each
side around axles.
Avoid brake and
hydraulic lines and
hydraulic rams.

Note: Insert steering lock

pin on articulating
machines prior to
chocking and chaining, if
provided.

Youre done!
Remember to turn off battery terminals
and cover exhaust stack.

Color Code:
Brown

Chocks

Blue

Nails

Red

Direct Lashings

21

Hiway Trailers
Click for next step
1.

Position trailer on
center of flat rack.

2.

Block under 5th

Wheel Attachment.
Lower landing gear
so blocking is snug
and secure. Block
tires and nail in
place.

3.

Secure to flat rack

with a minimum of 4
lashings on each
side to axles and
hard points around
landing gear. Avoid
air lines to brakes.

Youre done!

Color Code:
Brown

Chocks

Blue

Nails

Red

Direct Lashings

22

Spools
Click for next step
1.

Center spools on
platform.

2.

Block with timbers

across flat. Load
spools such that the
cross timbers are
supporting a portion
of the spool weight,
Spike into deck of
flat rack.
Block side cheeks of
spools with timbers.

3.
4.

Install Transverse
Lashings through
each center point on
each spool. 2 per
spool.

Youre done!
Note: Spools loaded to a
platform may roll
without chocks. Set
temporary chocks
prior to loading.
Color Code:
Brown

Blocking/Dunnage

Blue

HD Nails

Red

Half Loop Lashings

23

Cement Man Holes

1.

Position transverse
lumber bearers.

2.

Set cement flat on

the bearers

3.

Nail 4x4 dunnage

fore and aft to keep
cement from sliding

4.

Place protectors on
edges of cement for
protection from
chafing. Install direct
lashings from
cement holes to flat
rack. 2 per hole per
side.

Youre done!

Color Code:
Brown
Red

Bearers/Dunnage
Direct Lashings

Lt. Blue

Corner Protectors

24

KEY POINTS TO REMEMBER:

All chain to be hooked back to chain.
Chain to be hooked through chain tie down area on flat and run behind the yellow
rub rail.
Binders must be secured with wire or Zip-Ties.
Belly Bands are secured around cargo for unitization. Belly Bands should not be
attached to or wrapped around the flat rack.
Belly Banded product should be tight side to side to keep it from shifting and
loosening the chains.
All loose tag ends must be secured.
Do not cover picking points (holes at the top of each corner) of no post flats.
Indicate if flat is over width, over length, or over height.
Any portion of the load or lashing gear that extends beyond the flat to the left,
right, front or back is over sized for ocean shipping purposes and needs to be
declared. Any portion of the load that extends above the corner posts of the flat
is over height and need to be declared. Any load on a no corner post flat is
considered over height.
Do not use pallets as dunnage.
All Heavy Loads should be centered fore and aft on the flat rack based on the
cargos center of gravity.

25

Flat-Rack Loading Guidelines

Horizon Lines Contacts
Alaska Service:
Eddie Walton / Rick Wade

SLIDE MASTER: LEE FISHER

When it's too big for the box, we still deliver.

Your big cargo deserves big service. We expanded flat-rack capacity
on our vessels and added new flat rack equipment to provide reliable, safe transport for oversized shipments.
We're investing in new equipment to meet your needs today and tomorrow.
That's our promise. Always delivering.