Method of converting railcars

Abstract

A method of increasing the height of an autorack railcar comprising replacement of a conventional roof with an increased height roof assembly that includes integrated vertical side wall extensions, which avoid any need to provide side wall post extensions or additional side screens. The method may be used in conjunction with conversion of bi-level autorack railcars to tri-level autorack railcars, as well as with other conversions involving addition or removal of decks.

1 . A method of converting a bi-level auto-rack railcar to a tri-level autorack railcar, the bi-level autorack railcar comprising a first deck, a second deck above the first deck, a roof, side walls extending from the first deck to the roof, and end doors extending between the first deck and the roof, the side walls comprising series of posts arranged along each side of the railcar with vertical screens arranged between adjacent posts, the method comprising:
 removing the roof structure;   removing the second deck using an overhead crane;   installing a new second deck using an overhead crane;   installing a new third deck above the second deck using an overhead crane; and   replacing the roof structure with a new roof structure comprising a horizontal top center portion, inner intermediate portions extending downward and outward on each side of the top center portion, outer/lower intermediate portions extending downward and outward from the inner intermediate portions on each side of the roof structure, and vertical side wall extension portions extending downward from the outer/lower intermediate portions on each side of the roof structure to increase the height of the railcar without increasing the height of the side wall posts, and without adding side screens.   
     
     
         2 . The method of  claim 1  wherein the bi-level autorack car has a height of about 19 ft., 0 in. ATR, and is converted into a tri-level autorack car having a height of about 20 ft., 2 in., and wherein the vertical side wall extension portions have a vertical dimension of at least 12 in. 
     
     
         3 . The method of  claim 2  wherein the new roof structure comprises a series of corrugated sheets of galvanized steel joined by fasteners, and a pair of roof rails extending longitudinally along bottom edges of the vertical side wall extension portions and joined thereto, and wherein each of the roof rails consists of an angle member comprising a horizontal base portion and a vertical flange extending upward therefrom, and wherein the corrugated sheets are welded to the roof rails. 
     
     
         4 . The method of  claim 3  further comprising removing the end doors of the bi-level autorack railcar, and replacing them with end doors of increased height. 
     
     
         5 . The method of  claim 4  wherein replacing the roof with a new roof structure comprises removably attaching the new roof structure to the side walls. 
     
     
         6 . The method of  claim 4  wherein replacing the roof with a new roof structure comprises bolting the roof rails to upper ends of side wall posts. 
     
     
         7 . The method of  claim 6  wherein the tri-level railcar has a fully enclosed interior and an empty weight of no more than 116,000 lbs., and when fully loaded at up to about 24,000 lbs. per deck, has a Cg no greater than 98 in. ATR. 
     
     
         8 . The method of  claim 7  wherein the new roof structure is secured to the side walls by removable fasteners that are accessible from the interior but not from the exterior of the railcar. 
     
     
         9 . A method of converting a bi-level auto-rack railcar to a tri-level autorack railcar, the bi-level autorack railcar comprising a first deck, a second deck above the first deck, a roof, side walls extending from the first deck to the roof, and end doors extending between the first deck and the roof, the side walls comprising series of posts arranged along each side of the railcar with vertical screens arranged between adjacent posts, the method comprising:
 removing the roof structure;   lowering the second deck;   installing a new third deck above the second deck using an overhead crane; and   replacing the roof structure with a new roof structure comprising a horizontal top center portion inner intermediate portions extending downward and outward on each side of the top center portion, outer/lower intermediate portions extending downward and outward from the inner intermediate portions on each side of the roof structure, and vertical side wall extension portions extending downward from the outer/lower intermediate portions on each side of the roof structure to increase the height of the railcar without increasing the height of the side wall posts, and without adding side screens.   
     
     
         10 . The method of  claim 9  wherein the bi-level autorack car has a height of about 19 ft., 0 in. ATR, and is converted into a tri-level autorack car having a height of about 20 ft., 2 in., and wherein the vertical side wall extension portions have a vertical dimension of at least 12 in. 
     
     
         11 . The method of  claim 10  wherein the new roof structure consists of a series of corrugated sheets of galvanized steel joined by fasteners, and a pair of roof rails extending longitudinally along bottom edges of the vertical side wall extension portions and joined thereto, and wherein each of the roof rails consists of an angle member comprising a horizontal base portion and a vertical flange extending upward therefrom, and wherein the corrugated sheets are welded to the roof rails. 
     
     
         12 . The method of  claim 11  further comprising removing the end doors of the bi-level autorack railcar, and replacing them with end doors of increased height. 
     
     
         13 . The method of  claim 12  wherein replacing the roof with a new roof structure comprises removably attaching the new roof structure to the side walls. 
     
     
         14 . The method of  claim 13  wherein replacing the roof with a new roof structure comprises bolting the roof rails to upper ends of side wall posts. 
     
     
         15 . The method of  claim 14  wherein the tri-level railcar has a fully enclosed interior and an empty weight of no more than 116,000 lbs., and when fully loaded at up to about 24,000 lbs. per deck, has a Cg no greater than 98 in. ATR. 
     
     
         16 . The method of  claim 15  wherein the new roof structure is secured to the side walls by removable fasteners that are accessible from the interior but not from the exterior of the railcar. 
     
     
         17 . A method of increasing the height of an autorack railcar comprising a first deck, a second deck above the first deck, a roof, side walls extending from the first deck to the roof, and end doors extending between the first deck and the roof, the side walls comprising series of posts arranged along each side of the railcar with vertical screens arranged between adjacent posts, the method comprising:
 removing the roof structure; and   replacing the roof structure with a new roof structure comprising a horizontal top center portion, inner intermediate portions extending downward and outward on each side of the top center portion, outer/lower intermediate portions extending downward and outward from the inner intermediate portions on each side of the roof structure, and vertical side wall extension portions extending downward from the outer/lower intermediate portions on each side of the roof structure to increase the height of the railcar without increasing the height of the side wall posts, and without adding side screens; wherein the autorack railcar initially has a height of about 19 ft., 0 in. ATR, and is converted into an autorack car having a height of about 20 ft., 2 in.   
     
     
         18 . The method of  claim 17  wherein the vertical side wall extension portions have a vertical dimension of at least 12 in., and wherein the new roof structure comprises a series of corrugated sheets of galvanized steel joined by fasteners, and a pair of roof rails extending longitudinally along bottom edges of the vertical side wall extension portions and joined thereto, and wherein each of the roof rails consists of an angle member comprising a horizontal base portion and a vertical flange extending upward therefrom, and wherein the corrugated sheets are welded to the roof rails. 
     
     
         19 . The method of  claim 18  further comprising removing the end doors of the bi-level autorack railcar, and replacing them with end doors of increased height. 
     
     
         20 . The method of  claim 18  wherein replacing the roof structure with a new roof structure comprises bolting the roof rails to upper ends of side wall posts; and wherein the tri-level railcar has a fully enclosed interior and an empty weight of no more than 116,000 lbs., and when fully loaded at up to about 24,000 lbs. per deck, has a Cg no greater than 98 in. ATR; and
 wherein the new roof structure is secured to the side walls by removable fasteners that are accessible from the interior but not from the exterior of the railcar.