A METHOD OF PACKAGING RAILWAY WAGON COMPONENTS

Cross-Reference to Related Application

[0001] The present invention claims priority to Australian provisional patent application 2022900474 filed 28 February 2022, the entire contents of which are incorporated herein by reference.

Technical Field

[0002] The present invention relates to the field of railway wagons used to transport bulk materials via rail. The invention has been particularly developed for use with ‘gondola-type’ wagons used to transport ore. However, it will be appreciated that the invention may be applicable to other types of railway wagons.

Background of Invention

[0003] The following discussion of the background to the invention is intended to facilitate an understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application.

[0004] Railway wagons are large railway freight vehicles used to transport bulk goods such as coal, gravel, grain. Wagons (also known as ore wagons) are railway wagons used to carry ore materials such as iron ore from a mine site to a shipping port or to a processing or storage destination. Large mines operate many thousands of wagons creating ongoing demand for new wagons to replace those which have been damaged or decommissioned. Demand for new wagons is also created by the construction of new mines which require new railroad freight support.

[0005] Wagon production occurs at significant distance (and typically overseas) from mine sites. New wagons must normally be freighted, typically via sea and then by truck, from a manufacturing location to the operational destination. At present, wagons are typically assembled from components near to the component manufacturing location and then freighted as an assembled unit with two wagons often stacked vertically so as to minimise floor area occupation on freight vessels.

[0006] The freighting of wagons incurs significant transport and storage costs as well as detrimental environmental impacts in terms of carbon emissions from transport vehicles. Furthermore, the freight process involves significant logistical challenges in terms of reserving sufficient sea freight volume and sufficient storage volume at shipping docks where wagons must be stored until collection by a road or rail vehicle for the next leg of the freight process.

Summary of Invention

[0007] In view of the challenges and costs (both environmental and monetary) associated with current methods of transporting railway wagons such as wagons, there is a desire for an improved method of packaging railway wagons for transport.

[0008] According to an aspect of the present invention, there is provided a method of packaging wagon components for transport, including packaging together a plurality of wagon underframes with an underframe support arrangement to form an underframe package; packaging together a plurality of wagon side walls with a side wall support arrangement to form a side wall package; and packaging together a plurality of wagon end walls with an end wall support arrangement to form an end wall package, wherein each of the support arrangements are configured to facilitate the lifting and transport of the package to a wagon assembly location.

[0009] The method according to the invention advantageously minimises unoccupied volume during transport from a component manufacturing location to a wagon assembly location. In particular, the invention allows for a significant reduction in rail and sea freight volume for a given number of wagon components. As distinct from shipping assembled wagons which have a large unoccupied volume within each wagon, the packaging method of the present invention ships packages of like components in order to improve shipping volume utilisation. The resulting reduction in shipping volume per unit provides a reduction in carbon emissions insofar as more units can be shipped on a single freighter and therefore less freighters are required to ship a given number of units. Furthermore, a significant reduction in transport costs is achievable and particularly a reduction in sea freight costs which have significantly increased in recent times.

[0010] The invention allows for the packaged components to be transported with much greater efficiency to an assembly location nearer to the final operational destination. For example, the underframe, end wall and side wall packages may be transported to an assembly facility adjacent to a mine site where underframes, end walls and side walls are assembled together with wheels and other componentry to form a completed wagon ready for operation. In another example, the packages may be transported via sea freight to a port and then via rail or road to an assembly facility which is not necessarily adjacent to a mine site but with rail or road connection to a mine site. In this way, a significant reduction in sea freight carbon emissions and costs is still achieved having more efficiently transported the components during the sea freight leg which is typically the costliest part of the transport process in terms of emissions and monetary expense.

[0011] The present invention advantageously recognises that packaging together like components in discrete packages is more volume efficient than packaging together the different components of a single wagon in a ‘kit’ which would require additional packaging volume to fit the dissimilar components together in transportable package. For example, the total volume of three ‘like-component’ packages (i.e. one underframe package of underframes only, one end wall package of end walls only and one side wall package of end walls only) will be less than the total volume required to package the same components in multiple ‘kit’ packages each containing one underframe, two end walls and two side walls. In this regard, the packaging of like components further minimises the freight volume required to transport a given number of different components and thereby further reduces carbon emissions and further reducing transport and storage costs.

[0012] The method of the invention further involves maintaining the wagon components in a spaced apart arrangement so as to prevent or reduce the risk of damage occurring during transport. The components of each package are maintained in the spaced apart arrangement by a corresponding support arrangement which is specifically configured for each component type and is therefore unique to each of the three different packages. The support arrangements may be configured to support and maintain the components in a volume-minimising arrangement. The support arrangements may also facilitate lifting of the packages by providing lifting points.

[0013] In some embodiments, one or more of the support arrangements may provide a degree of mechanical protection against external impacts. For example, one or more of the support arrangements may be arranged at a periphery of the respective wagon components. Portions of the support arrangements may be located externally of the wagon components and or partially encompass or fence or bound the components which may be provide a barrier against impacts experienced during freighting.

[0014] In a particular form of the invention, the support arrangement of each package supports the plurality of wagon components in a row or stack. It will be appreciated that wagon underframes (sometimes known ‘chassis’), end walls and side walls may have a generally planar configuration and therefore a row arrangement or stacked arrangement may advantageously increase the number of components per unit volume. The wagon components in the packages may be arranged to minimise unoccupied volume within the package. For example, adjacent components in a package may be arranged relatively close to one another. In particular, components may be placed as close as practical whilst maintaining sufficient spacing so as to avoid contact between adjacent components which could cause damage during transport.

[0015] Used herein, the term ‘underframe’ will be appreciated to describe the component of a gondola-type rail wagon beneath the end walls and side walls and to which the wheel assemblies (sometimes known as ‘bogies’) are fitted.

[0016] In a particular form of the invention, the components may be arranged to minimise unoccupied volume by being arranged in a parallel configuration. For example, a plurality of planar end walls in the end wall package may be arranged in a row or stack of parallel components.

[0017] In a form of the invention, the components of each package are in a spaced apart arrangement which has approximately even spacing between adjacent components. As noted, the spacing between adjacent components may be selected so as to provide the minimum spacing for greater component density whilst having sufficient spacing to minimise the chance of component contact during transport. Once an optimal spacing has been identified (which will typically depend on the shape, dimensions and configuration of the particular component) the use of even spacing between adjacent components can therefore further optimise volume efficiency.

[0018] In a form of the invention, one or more of the support arrangements are configured to maintain the respective wagon components in a spaced apart arrangement.

[0019] In a particular form of the invention, each package is configured to permit one-by-one component removal during unpackaging of the wagon components. This may advantageously streamline assembly of the wagons at the wagon location in that components can be removed from the packages one at a time and only when required. The packages may be configured to facilitate discrete component removal in that spacing is provided between adjacent components into which a lifting tool can be inserted to lift a discrete component. For example, in an embodiment of the invention in which components are vertically stacked in a package, the spaced apart arrangement can enable a lifting device such as a crane or forklift to vertically lift the top component from the stack without contacting or disturbing the rest of the stacked components.

[0020] Similarly, in a package where components are arranged in a row, the package may be configured to retain each individual component in position such that removal of one component will not affect adjacent components. For example, a row of components may be individually retained in a row formation by the support arrangement which may include individual retention elements securing each component to the support arrangement. Consequentially, the removal of one component from the end of the row of components does not risk the remaining components to tip, fall over or fall out of the package.

[0021] In a form of the invention, each package is configured with lifting points to facilitate lifting of the package by an overhead lifting device. The lifting points may comprise any suitable configuration such as an opening for receiving a strap or chain, or an anchoring point or a projection or a loop for receiving or engaging with a lifting strap or lifting chain or any other lifting member. In a form of the invention, the packages may be provided with rigid loops allow convenient connection with lifting straps.

[0022] The lifting points may be provided on the support arrangements of the package so that lifting load is transmitted through the support arrangement rather than through the wagon components of the package. The support arrangement of each package may be configured to support the entire load of that package and to permit lifting of the package via lifting of the support arrangement.

[0023] In a form of the invention, the underframes of the underframe package are orientated horizontally and positioned vertically with respect to one another in a stacked arrangement (i.e. a layered arrangement). In a particular form of the invention, the underframe package comprises a stack of four underframes though it will be appreciated that larger or smaller stacks are possible. It will be appreciated that wagon underframes are designed for horizontal orientation during operation (i.e. parallel with the ground surface) and therefore this form of the invention packages the underframes in their intended orientation. The underframes of the underframe package are thereby not exposed to unusual load distributions for which they have not been engineered as might be the case if the underframes were packed on their sides or ends. The vertically stacked arrangement of underframes may advantageously reduce the amount of floor space required in a package of several underframes need only occupy the floor space of a single underframe.

[0024] The underframes may be spaced apart from each other in the stacked arrangement by the underframe support arrangement which may comprise a plurality of supports positioned between vertically adjacent underframes, and with each underframe supported by at least one of the supports located below the respective underframe. The underframe package may therefore comprise a stack or tower of successive supports and underframes. The body bolsters of the underframes and the legs of the supports may form four vertical support columns. Each vertical support column may comprise a stack of alternating body bolsters and legs, each body bolster overlying an upper end of a leg and a plurality of the legs standing on one of the body bolsters. [0025] For example, the underframe package may comprise a first or lowermost support on a ground surface, a first or lowermost underframe on the first support, a second support above the first underframe, a second underframe on the second support, a third support above the second underframe, a third underframe on the third support and so on. The supports of the underframe package may thereby act as spacers and whereby the underframes are spaced from one another by the height of the supports

[0026] The supports could have various configurations and dimensions. Each underframe may be supported by a single support or, alternatively, may be supported by a plurality of discrete supports which cooperate to support the respective underframe. For example, each underframe could be supported by two or more spaced apart supports with each of the supports supporting different parts of the underframe. In a form of the invention, the supports comprise legs and each underframe is supported by a plurality of legs positioned to support different parts of the underframe. The legs may be positioned at a periphery of the underframe.

[0027] According to a particular embodiment, each underframe is supported on a pair of supports and with each support comprising a paid of legs connected by a cross-member. Each support may have a H-shaped configuration with a generally horizontal cross-member extending between the pair of legs. The pair of legs in each support may be spaced apart by approximately the width of an underframe. The cross-member may extend from the legs between an upper end and lower end of the legs. In a particular form of the invention, the cross-member extends from a position on the legs that is closer to the lower end of the legs than the upper end.

[0028] The pair of supports which support the underframe may be spaced apart from one another such that each support supports a different part of the underframe. It will be appreciated that wagon underframes are generally rectangular in profile with a longitudinal axis that extends between a pair of opposing ends. The pair of supports may be spaced apart from one another along the longitudinal axis of the underframe.

[0029] The legs of the supports may have any suitable configuration. In a particular form of the invention the legs include a lower plate, an upper plate and an elongate portion extending between the upper and lower plates. In a form of the invention the upper and lower plates are square-shaped and the elongate portion has a square profile. According to a form of the invention, the supports in the underframe package are arranged in two columns with the supports of each column positioned vertically with respect to one another. In a form of the invention, a part of the underframes is positioned between each support in each column. For example, a support point, jacking point, lifting point or any other structural point of a first the underframe may be positioned (and supported by) the upper end of the legs and then the legs of the next support in the column is located atop the support point of the first underframe, followed by the support point of the second underframe in the stacked arrangement, and so on.

[0030] In a particular form of the invention, each underframe includes four lift points configured for cooperatively supporting the weight of the underframe and each of the four lift points is supported by an upper end of one of the legs. In a particular embodiment, each underframe may include a pair of opposite longitudinal side edges and two of the four lift points are located at each side edge. In a form of the invention, the lift points on each longitudinal side are positioned toward the opposite ends of the underframe such that the four lift points are positioned adjacent to the four corners of the underframe. The lift points may comprise a structural projection, shelf, sill, flange, beam or any other suitable point at which the underframes can be lifted.

[0031] In a form of the invention, the lift points are on a body bolster of the underframe. It will be appreciated that the body-bolsters are a support structures extending from centre sills (the centre box section of the underframe structure).

[0032] In a form of the invention, the body-bolsters have a planar upwardly-facing surface and a planar downwardly-facing surface and wherein the downwardly-facing surfaces are arranged to overlie the upper ends of the legs. The body bolsters may have a generally square profile and therefore the upper ends of the legs may be provided with a generally square profile of approximately corresponding size to the body bolsters. In this way, the legs of the supports may be configured to correspond or match with the body bolsters of the underframes so as to facilitate stacking of successive underframes and supports into the stacked arrangement which may resemble a column or tower of underframes and supports. [0033] In a form of the invention, at least one of the underframes is supported by legs which stand upon the upwardly-facing surfaces of body bolsters of a lower underframe in the stacked arrangement. In a particular form of the invention, the stacked arrangement includes four underframes comprising a lowermost underframe, a second underframe positioned above the lowermost underframe, a third underframe positioned above the second underframe and top underframe positioned above the third underframe and wherein the top underframe is supported by legs which stand upon the upwardly-facing surfaces of body bolsters of the third underframe, the third underframe is supported by legs which stand upon the upwardly-facing surfaces of body bolsters of the second underframe and the second underframe is supported by legs which stand upon the upwardly-facing surfaces of body bolsters of the lowermost underframe.

[0034] According to this embodiment of the stacked arrangement of underframes, the body bolsters of the lowermost, second and third underframes are therefore sandwiched between the upper ends of legs below the respective underframe and the lower ends of legs above the respective underframe. The body bolsters and legs may be directly vertically aligned so as to form a vertical tower or column of successive legs and body bolsters. As noted, each underframe may have four body bolsters (two at either longitudinal side) and each underframe may be supported by a pair of supports each having two legs. Accordingly, the underframe package may include four columns of successive support legs and body bolsters. According to this configuration, load (for example the weight of the underframes) may be transmitted through the vertical columns of legs and body bolsters and directly to the ground surface.

[0035] In a form of the invention the upper ends of the legs include a locating abutment facilitating positioning of the body bolsters on the upper ends of the legs. The locating abutment may comprise an upwardly extending protrusion which helps align the underframe body bolsters onto the upper end of the support legs when the underframes are being lowered onto the legs by a crane or similar lifting device.

[0036] In a form of the invention, each body bolster is securely mounted to the upper ends of the respective leg. That is, each underframe is secured to the supports directly beneath it. The secure mounting may be provided in a variety of configurations but in a particular form of the invention, the upper ends of the legs are provided with at least one mounting bracket for securely mounting the body bolsters to the upper ends of the legs. In a form of the invention, more than one mounting bracket is provided and in a particular form of the invention, each leg includes three mounting brackets. The mounting brackets may comprise a clamp configuration with a clamp plate connected to the upper end of the leg via adjustable bolts and whereby tightening of the bolts moves the clamp plate downward toward the upper end of the legs in order to clamp the body bolsters to the upper end of the legs.

[0037] In a particular form of the invention, the mounting brackets are configured to clamp onto a lip at the base of the body bolsters. As previously noted, the legs can a square shaped lower plate and a square shaped an upper plate and an elongate portion extending between the upper and lower plates. In a form of the invention, the upper plate is located at the upper end of the legs and the lower plate is located at the lower end of the legs and the upper plate is larger than the lower plate. Enlargement of the upper plate relative to the lower plate may provide additional space for the mounting brackets to be secured at the upper end of the legs.

[0038] In a form of the invention, the lower plates of the legs are placed in contact with the upwardly-facing surfaces of the body bolsters (except for the legs supporting the lowermost underframe which will typically have lower plates in contact with the ground surface). The upper plates of the legs may be placed in direct contact with the downwardly-facing surfaces of the body bolsters. Alternatively, in a particular form of the invention, the upper ends of the legs may include a resilient support pad. For example, a resilient pad may be provided atop the upper plate which provides a degree of cushioning or movement absorption within the structure of the stacked arrangement. The resilient pad may permit slight relative movement between the legs and the underframes and may also reduce the possibility of damage occurring to the downwardly-facing surface of the body bolsters when placed upon the upper ends of the legs. According to this embodiment, the resilient support pad is therefore sandwiched between the upper plate of its respective leg and the downwardly-facing surface of the underframe body bolster. The resilient support pad may comprise a rubber pad. The resilient support pad mad be secured (for example adhered, fitted or fixed) to the upper ends of the legs or, alternatively, the support pads may be loosely placed atop the upper ends of the legs.

[0039] In a form of the invention, each underframe is secured via bindings to a higher and/or a lower underframe in the stacked arrangement. The bindings may comprise any suitable configuration such as straps, ropes, chains, bands, tethers or similar. In a form of the invention, the bindings include coupler bindings connecting the coupler shanks of one or two vertically adjacent underframes in the stacked arrangement. The bindings themselves may therefore be orientated generally vertically when extending between the vertically adjacent couplers. The couplers of underframes which are positioned between a lower underframe and a higher underframe (for example, the 2 ^nd and 3 ^rd underframe positions) may be secured by two bindings, one extending upward to the higher underframe and one extending downward to the lower underframe.

[0040] In a form of the invention, the bindings including side edge bindings connecting longitudinal side beams (known as clamp sills) of each underframe to the clamp sills of one or two vertically adjacent underframes in the stacked arrangement. Each clamp sill each underframe in the stacked arrangement may have a pair of spaced apart bindings. The bindings may operate to secure the stack of underframes together in order to prevent or resist relative movement between the underframes. Each underframe may be bound via bindings to only the directly vertically adjacent underframes in the stacked arrangement or, alternatively, one or some or all of the underframes may be bound to each of the other underframes in the stacked arrangement.

[0041] The stacked arrangement of underframes and supports may therefore be connected together as a secure structure via the use of bindings which connect adjacent underframes to one another and a mounting arrangement at the upper end of the legs which connects each underframe to the legs on which it is supported.

[0042] The underframe package may be lifted by a lifting device such as a crane via connection of lifting tethers to the lowermost underframe. In particular, lifting tethers may be connected to a longitudinal side beam of the lowermost underframe such as a clamp sill of the lowermost underframe. Lifting from the clamp sills on the lowermost underframe lifts the lowermost underframe as well as the supports and underframes stacked on top of the lowermost underframe. The supports beneath the lowermost underframe are lifted by virtual of the mounting connection between the lowermost underframe and the upper ends of the legs beneath the lowermost underframe.

[0043] In a form of the invention in which the underframe package comprise four underframes, the total dimensions of the underframe package may be approximately 10529mm length, 3300mm width and 3700m height. It will be appreciated that the dimensions of the underframe package will depend on the number of underframes in the underframe package and that this may vary. In alternative forms of the invention, the underframe package may comprise less than four or more than four underframes.

[0044] In a particular application of the invention in which underframes of the underframe package are required to be transported by truck, an underframe package of four underframes may be conveniently split into two stacks of two underframes in order to meet certain truck height restrictions (if applicable). That is, the underframe may be transported via sea freight in an underframe package of four underframes and then subsequently broken into two packages of two underframes for a road portion of the transportation process.

[0045] Each underframe may also be configured for individual lifting, for example via connection of lifting tethers to the clamp sills of each underframe. Individual underframe lifting may be used during packaging when each underframe is individually placed into the stacked arrangement (e.g. via a crane or other overhead lifting device) and also during unpackaging of the underframe package when each underframe is individually removed from the stacked arrangement at the assembly location.

[0046] In a form of the invention, the side wall support arrangement secures the side walls of the side wall package in a side wall row wherein the side walls are upstanding and side-by-side and parallel with respect to one another. It will be appreciated that wagon side walls are generally planar and rectangular in profile such that their length is greater than their height. The side wall row comprises side walls which are upstanding which will be understood as meaning the side walls are in their operational orientation meaning they are orientated upright with a longitudinal axis that is generally horizontal and a height axis (an axis extending between opposite longitudinal sides) which is generally vertical.

[0047] The side wall support frame may have dimensions that are greater than that of the side wall row. The side wall row may be contained within the dimensions of the side wall frame. In a form of the invention, the side wall row is bounded on all sides by portions of the side wall support arrangement. For example, the side wall support arrangement may include portions on all sides of the side wall row. As mentioned in the foregoing, this may provide a degree of mechanical protection against external impacts. The side wall support arrangement may be arranged to partially surround the periphery of the side wall row in that each side (including the top and bottom) of the side wall row is adjacent to part of the side wall support arrangement. The side wall support arrangement partially envelop or fence or bound the side wall row which may be provide a barrier against impacts experienced during freighting.

[0048] In a form of the invention, the side wall support arrangement comprises a side wall frame including a rectangular base having a pair of opposite longitudinal sides and a pair of opposite ends. In a form of the invention, the sides and ends comprise steel U-sections. The base may have a width and length which are slightly greater than a width and a length of the side wall row.

[0049] The side wall frame may include four corner uprights, each upstanding from one of the four corners of the rectangular base, the four corner uprights comprising two pairs of corner uprights and with one pair at each of the opposite ends of the base, the side wall frame further including upper end cross-members extending between upper ends of each pair of corner uprights and along upper corners of the side walls in the side wall row. The upper end cross-members may extend parallel to the opposite ends of the base. The upper end cross-members may be positioned vertically above the opposite ends of the base. The upper end cross-members may therefore be positioned at opposite upper corners of the side wall frame and are spaced from one another by approximately the length of the longitudinal sides of the base. [0050] The upper end cross-members may include a plurality of projections for supporting the side walls and wherein edges of the side walls are received in openings between adjacent projections, the openings being equidistantly spaced along a length of the upper end member and positioned to maintain the side walls in the spaced apart arrangement. The projections on each upper end cross-member may be orientated toward the projections of the other upper end cross-member at the opposite end of the side wall frame. The projections may be provided on a vertical face of the upper end cross-members.

[0051] The projections may comprise a row of brackets, protrusions or any other configuration which forms openings or spaces therebetween for receiving edges of the side walls. In a form of the invention, the projections comprise pairs of L-shaped brackets. In a form of the invention, each pair of L-shaped bracket is secured to the upper end cross-member in a spaced apart configuration so as to form an opening between each pair and in which an edge of a side wall is located.

[0052] The brackets may be removably connected to the upper end crossmembers so as to facilitate convenient loading and removal of the side walls from the side wall frame. Furthermore, the removable connection may allow for one-by-one removal of the side walls during unpacking of the side wall package. For example, removing a first side wall from the side wall package may involve removing one of the brackets which retains the first wide wall edge in position.

[0053] In a form of the invention, the side walls may be lifted via a lifting spreader bar with clamps designed to attach to a horizontal upper edge of the side walls such as an upper cant rail of the side walls. The loading procedure may involve lowering each side wall into position within the side wall frame and with the spreader bar supporting the side wall in position whilst the brackets are manually attached to the upper end cross-members. The removal procedure may involve the lifting spreader bar being attached to the upper cant rail of a side wall and the alignment of the spreader bar being checked to ensure it is aligned vertically with respect to the attached side wall. The brackets may then be removed and the side wall lifted vertically until clear of the side wall frame. [0054] In a form of the invention, the side wall frame includes a plurality of side uprights upstanding from the longitudinal sides of the base and a plurality of top cross-members extending between upper ends of the side uprights and above tops of the side walls in the side wall row. The top cross-members may extend parallel with the opposite ends of the rectangular base and also with the upper end crossmembers (i.e. perpendicular to longitudinal axes of the side walls). The top crossmembers may be generally horizontal and extend across the tops of all of the side walls in the side wall row. The corner uprights and side uprights may be approximately the same length such that the top cross-members are at approximately the same level as the upper end cross-members. In a form of the invention the side wall frame includes three pairs of side uprights and three corresponding top crossmembers. It will be appreciated that the top cross-members may be removably connected to the upper ends of the side uprights to allow removal during loading and unloading of the side walls into the side wall frame.

[0055] In a form of the invention, the base includes a pair of longitudinal side members, a pair of end members and a plurality of base cross-members located intermediate of the end members and extending between the side members, the base cross-members including a plurality of recesses and each recess receiving a portion of one of the side walls. In a form of the invention, a base of each side upright is mounted to the longitudinal side members of the base. In a form of the invention, a base of each corner uprights is mounted to the longitudinal side members of the base at opposite ends of the longitudinal side members i.e. adjacent to an intersection between the longitudinal side members and the opposite end members.

[0056] In a form of the invention, the top cross-members are aligned with the bases of the side uprights such that the base cross-members are also aligned with the top cross-members. Each of the top cross-members may therefore extend parallel to and vertically above one of the base cross-members.

[0057] In a form of the invention, the side wall portions that are received in the recesses are lower portions of elongate stiffening ribs of the side walls. For example, the stiffening ribs may comprise vertical stanchions of the side walls which slot into the recesses to brace the side wall from bending due to wind loading whilst in truck transit. Receipt of the side wall stiffening ribs in the base cross-member recesses may therefore retain the lower edges of the side walls in position within the side wall frame. The recesses in the base cross-member and the openings in the upper end cross members may together retain both the upper and lower edges of the side walls in position within the side wall frame.

[0058] The corner uprights, side uprights, base end members, base side members, base cross-members, upper end cross-members and top cross-members may have various configurations such as a post, beam, pole, extrusion or other rigid elongate structure. The components of the side wall frame may be formed of steel. In a form of the invention the side uprights and corner uprights are steel beams. In a form of the invention the base is formed of steel l-sections or C-sections or any other suitable cross-section of steel beam. Similarly, the upper end cross-members and top cross-members may be formed of steel and, in particular steel C-sections.

[0059] According to a form of the invention, the method includes the additional step of vertically stacking a pair of side wall packages, the pair of packages comprising an upper package and a lower package and wherein the side wall frame of the upper package is seated upon the side wall frame of the lower package. This configuration may advantageously allow for a double stack of side wall packages to be transported or stored in the floor area of a single package. The double stacking of side wall packages may be particularly advantageous during sea freight.

[0060] In a particular form of the invention, the top cross-members include a channel and the base cross-members of the upper package are received within the channels of the top cross-members of the lower package. The top cross-members may include a U-shaped portion with a channel configured in size to receive the base cross-members of the upper side wall package. In this manner, the upper and lower side wall packages may be mated together to form a double stack of side wall packages. Receipt of the base cross-members of the upper package into the top cross-members of the lower package advantageously resists or prevents relative movement between the packages in the longitudinal direction.

[0061] The U-shaped portion of the top cross-members may terminate before the opposite ends of the top cross-members such that the opposite ends of the top crossmembers are provided by a flat portion configured to underlie the base of the upper side member package which is placed atop the lower side wall package in the double stack of side wall packages.

[0062] In a form of the invention, the base includes a plurality of lifting points configured for connection with a lifting device. The lifting points may comprise openings for receiving a lifting tether. In a form of the invention, the base includes steel stiffeners fitted around the base of the side uprights and each stiffener includes an opening for receiving a lifting tether. In a form of the invention, the base includes strapping projections configured for receiving strapping which wraps around the side wall row for additional security. The strapping projections may comprise rigid loops extending upwardly from the base. The side wall package may include a plurality of straps extending across a top of the side wall row and connecting to the base.

[0063] In a form of the invention, the side wall row includes seven side walls. In a particular embodiment of a seven side wall package, and the side wall frame has external dimensions of approximately 9700mm length, 3050mm width and 2500mm height. The selection of seven side walls in the side wall row may advantageously enable the side wall package to be transported by truck.

[0064] In forms of the invention where the side wall row is be contained within the dimensions of the side wall frame, these dimensions will therefore also be the external dimensions of the side wall package. In forms of the invention where two side wall packages are stacked vertically, the height dimension of the double stack may be approximately 4900mm. The double stack may have a height dimension slightly less than double the height dimension of a single package due to the base cross-members of the upper package being seated within the top cross-members of the lower package.

[0065] In a form of the invention, the end walls of the end wall package are arranged in an end wall stack in which the end walls are orientated horizontally and positioned vertically with respect to one another in a stacked arrangement.

[0066] In a form of the invention, the end wall support arrangement have dimensions that are greater than that of the end wall stack. The end wall stack may be contained within the dimensions of the end wall support arrangement. In a form of the invention, the end wall stack is bounded on all sides by portions of the end wall support arrangement. For example, the end wall support arrangement may include portions on all sides of the end wall stack.

[0067] The end wall support arrangement may include elongate spacers located between vertically adjacent end walls in the end wall stack. The spacers may comprise a rubber material and may maintain all or part of the end walls in a spaced apart arrangement so as to reduce the possibility of damage occurring during transport.

[0068] The end walls may include an inside face configured to face inwardly once assembled into a complete wagon (i.e. into the interior of the wagon) and an outside face configured to face outwardly from the assembled wagon. In a form of the invention the end wall stack is arranged with the inside faces orientated downward for improved protection during transport against objects which might be dropped onto the end wall package.

[0069] In a form of the invention, the end wall support arrangement comprises an end wall frame including a rectangular base. The rectangular base may have a length and width slightly larger than the length and width of the end walls in the end wall stack. The rectangular base can include a pair of longitudinal side members, a pair of end members and a plurality of base cross-members located intermediate of the end members and extending between the side members.

[0070] In a form of the invention, the end wall frame further includes side uprights upstanding from each of the longitudinal side members of the base and top crossmembers extending between upper ends of the side uprights and above a top of the end wall stack. The end wall stack may be bounded on all sides by a portion of the end wall frame. The end wall frame may further include end uprights upstanding from each of the end members of the base. The end wall stack may therefore be bounded on each of its four vertical sides by one of the side uprights or end uprights and bounded at its top by the top cross-members and bounded at its underside by the base.

[0071] A form of the invention involves the additional step of vertically stacking a pair of end wall packages, the pair of packages comprising an upper package and a lower package and wherein the end wall frame of the upper package is seated upon the end wall frame of the lower package. In a form of the invention, the top crossmember includes a channel and the base cross-members of the upper package are received within the channels of the top cross-members of the lower package. The top cross-members of the end wall frame may have a similar or equivalent configuration to the top cross-members of the side wall frame discussed in the foregoing. In particular, the top-cross members may comprise a steel C-section or a steel beam with a partial C-section providing a channel which is configured in size for the base cross-members to be received and seated within the top cross-member. This configuration may advantageously prevent or relative movement in a longitudinal direction between two end wall packages in a double stack.

[0072] In a form of the invention, the base of the end wall frame includes a plurality of lifting points configured for connection with a lifting device. The lifting points may be provided on steel stiffeners fitted at a lower end of the side uprights and could comprise, for example, an opening in the steel stiffeners through which a lifting tether can be fed.

[0073] In a form of the invention, the end wall base further includes strapping points such as strapping protections. The strapping projections may comprise rigid loops extending upwardly from the end wall base. The end wall package may include a plurality of straps extending across a top of the end wall stack and connecting to the base In a form of the invention the end wall stack includes at least one strap extending over a top of the end wall stack and connected to the each of the opposite longitudinal side members of the base and at least one strap extending over a top of the end wall stack and connected to each of the opposite end members of the base.

[0074] The loading and unloading procedure for placing and removing end walls into the end wall frame may involve a spread bar lifting beam with clamps designed to fit to the end wall. For example, clamps designed to fit onto a channel each end wall. Padding such as rubber sheeting may be used between each layer to protect the end walls. The end walls may be lifted into place vertically by the spread bar lifting beam and then lowered onto wooden gluts before being laid flat.

[0075] In a form of the invention, the end wall package includes ten end walls. In a particular embodiment of a ten end wall package, the end wall frame has external dimensions of approximately 3400mm length, 2400mm width and 2000mm height. In forms of the invention where two end wall packages are stacked vertically, the height dimension of the double stack may be approximately 3900mm. The double stack may have a height dimension slightly less than double the height dimension of a single package due to the base cross-members of the upper package being seated within the top cross-members of the lower package. The double stacking of end wall packages may be particular advantageous during sea freight.

[0076] It will be appreciated from the foregoing that the present invention therefore provides an improved method of packaging wagon components for transport. It will be appreciated that this packaging method can be implemented in a corresponding improved method of transporting wagon components.

[0077] In this regard, an aspect of the invention provides, a method of transporting railway wagon components to a wagon assembly location, the method including the steps of packaging wagon components according to the above-discussed method of packaging; and transporting an underframe package, a side wall package and an end wall package to the wagon assembly location.

[0078] In a further aspect of the invention there is provided, a method of transporting railway wagon components to a wagon assembly location, the wagon components comprising a wagon underframe, wagon end walls and wagon side walls and the method including; packaging together a plurality of wagon underframes with an underframe support arrangement to form an underframe package, the underframe support arrangement maintaining the underframes in a spaced apart arrangement; packaging together a plurality of wagon end walls with an end wall support arrangement to form an end wall package, the end wall support arrangement maintaining the end walls in a spaced apart arrangement; packaging together a plurality of wagon side walls with a side wall support arrangement to form a side wall package, the side wall support arrangement maintaining the side walls in a spaced apart arrangement; transporting the underframe package, end wall package and side wall package to the wagon assembly location.

[0079] It will be appreciated that the numerous optional features and configurations associated with the previously discussed method of packaging wagon components will also be applicable to said method of transporting wagon components.

[0080] As noted in the foregoing, the railway wagon which is the subject of the present invention may be a gondola-type wagon and, in particular a gondola-type ore car. Accordingly, in a form of the invention, the above-discussed method of packaging railway wagon components for transport is a method of packaging ore car components. Similarly, the above-discussed methods of transporting railway wagon components may be a method of transporting ore car components.

[0081] It will be appreciated that this inventive concept may be applied to a variety of other railway wagons and, for example, hopper cars/hopper wagons such as those with a bottom-dumping or side-dumping configuration. In this instance, it is envisaged that the packaging frames could be reconfigured (for example, dimensionally) to accommodate the componentry of different railway wagons such as hopper cars or other types of railway wagons.

Brief Description of Drawings

[0082] In order that the invention may be more fully understood, some embodiments will now be described with reference to the figures in which:

[0083] Figures 1 and 1a illustrate an existing method of transporting assembled wagons;

[0084] Figure 2 is a perspective view of a package of wagon underframes according to an embodiment of the present invention;

[0085] Figure 3 is perspective view of a support assembly used in the package of underframes shown in Figure 2;

[0086] Figure 4 is a front view of the support assembly of Figure 3;

[0087] Figure 5 is a top view of the support assembly of Figure 3 and 4;

[0088] Figure 6 is an end view of a support pillar of the support assembly of

Figures 3 to 5; [0089] Figure 7 is a top view of the support pillar of Figure 6;

[0090] Figure 8 is a side view of the support pillar of Figures 6 and 7;

[0091] Figure 9 is a perspective view of the support pillar of Figures 6 to 8 supporting an underframe lifting point and a second support pillar;

[0092] Figure 10 is a perspective of a first end of the underframe package shown in Figure 2;

[0093] Figure 11 is a perspective view of a second end of the underframe package shown in Figure 2;

[0094] Figure 12 is a side perspective view of a portion of the underframe package shown in Figure 2;

[0095] Figure 13 is a perspective view of a package of wagon side walls according to an embodiment of the present invention;

[0096] Figure 14 is a perspective view of the side wall package of Figure 13 connected to an overhead lifting beam;

[0097] Figure 15 is a perspective view of a packing frame used in the side wall package of Figures 13 and 14;

[0098] Figure 16 is a top view of the side wall packing frame of Figure 15;

[0099] Figure 17 is a perspective view of a double-stack of the side wall packages of Figure 13;

[0100] Figure 17a is a perspective sectional view of a portion of the double-stack of side wall packages in Figure 17.

[0101] Figure 18 is a closer perspective of a cross-member of the side wall packing frame of Figures 15 and 16;

[0102] Figure 19 is closer perspective of a lifting point on side beam of the side wall packing frame of Figures 15 and 16; [0103] Figure 20 is an end view of the side wall package of Figure 13;

[0104] Figure 21 is a perspective view of the top of the side wall package of

Figure 13;

[0105] Figure 22 is a perspective view of a package of wagon end walls according to an embodiment of the present invention;

[0106] Figure 23 is a perspective view of a packing frame used in the end wall package of Figure 22;

[0107] Figure 24 is a side view of the end wall packing frame shown in Figure 23;

[0108] Figure 25 is perspective view of end wall package of Figure 23 connected to an overhead lifting beam; and

[0109] Figure 26 is a perspective view of a double-stack of the end wall packages of Figure 23.

Detailed Description

[0110] Figure 1 illustrates a side view of an existing method of transporting a pair of assembled wagons comprising gondola-type ore cars 1. The ore cars 1 are transported in a double stack 2. Figure 1 a illustrates an end view of the double stack 2. Each of the ore cars 1 are positioned on four support legs 3 with the legs 3 supporting the upper ore car 1 standing upon an upper edge of the lower ore car 1 and the legs 3 supporting the lower ore car 1 standing on a ground surface. It will be appreciated from Figure 1 that this method of transporting two ore cars 1 requires a relatively large freight volume and which includes unoccupied volume within the ore cars and between the wheel arrangements of the ore cars 1 .

[0111] Turning to Figure 2, there is illustrated an underframe package 10 which includes four ore car underframes 12 in a stacked arrangement whereby the underframes 12 are positioned vertically with respect to one another. The underframes 12 are stacked in a parallel configuration and with approximately even spacing therebetween. The stack of four underframes comprises a lowermost underframe 12a, a second underframe 12b above the lowermost underframe 12a, a third underframe 12c above the second underframe 12b and a top underframe 12d above the third underframe 12c. The underframes 12 are orientated horizontally or parallel with the ground surface G on which the underframe package 10 is located. It will be appreciated that ground surface G may be the floor of a storage facility or a transportation vehicle such as the deck of a ship, the floor of a rail car or the base of a truck trailer or any other surface on which the underframe could be stored or transported.

[0112] Each underframe 12 include a pair of opposite longitudinal sides 20 and a pair of opposite ends 21. Each longitudinal side 20 includes a pair of body bolsters 22. The four body bolsters 22 of each underframe 12 are configured to cooperatively support the weight of the respective underframe 12.

[0113] The underframe package 10 includes an underframe support arrangement comprising eight identical supports 14 configured to support the underframes 12. In particular, the underframes 12 are supported by their respective body bolsters 22 which are positioned on the supports 14. Each underframe 12 is located on a pair of the supports 14. Each of the supports 14 is positioned adjacent one of the opposite ends 21 of the underframes 12.

[0114] Referring to Figures 2, 3 and 4, the supports 14 each include a pair of legs 16 and a cross-member 18 extending between the pair of legs 16. As shown in Figure 4, the cross-member 18 extends from the legs 16 from a position on the legs 16 that is closer to a lower end 16a of the legs than an upper end 16b. As shown in Figures 4 and 5, the support 14 may also include two pairs of diagonal reinforcement struts 17 with one pair of struts 17 extending between each leg 16 and a top surface 18a of the cross-member 18.

[0115] The upper end 16b of each leg 16 includes a locating abutment 19 which facilitates positioning of the underframes on the upper ends 16b of the legs 16. The locating abutment comprising a projection upstanding from the upper ends 16b. As shown in Figure 9, the body bolster 22 of the underframe 12 is seated on the upper end 16b and abuts the locating abutment 19. The locating abutment 19 helps locate the body bolster 22 into position on the upper end 16b during lowering of the underframe 12 onto the leg 16. The body bolsters 22 include a planar upwardly-facing surface 24 (best shown in Figure 2) and a planar downwardly-facing surface 26 which (as best shown in Figure 9) overlies the upper ends 16b of the legs 16.

[0116] As noted, each underframe 12 is supported by two supports 14, each comprising two legs 16 and therefore each underframe 12 is supported by four of the legs 16. The legs 16 have a height slightly larger than a height of each underframe 12 such that the supports 14 maintain the underframes 12 in a spaced apart arrangement but whilst minimising the spacing so as to minimise unoccupied volume within the package and also minimising the overall height dimension of the underframe package.

[0117] As seen in Figure 2, the second, third and top underframes 12b, 12c, 12d are supported by legs 16 which stand upon the body bolsters 22 of a lower underframe 12 in the stacked arrangement. In particular, these legs 16 stand upon the upwardly-facing surfaces 24 of body bolsters 22 of a lower underframe. A closer view of this arrangement is shown in Figure 9 in which the lower end 16a of a higher leg in the stacked arrangement is shown standing upon the body bolster 22.

[0118] Returning to Figure 2, the top underframe 12d is supported at its body bolsters 22d by legs 16d which stand upon the body bolsters 22c of the third underframe 12c. The third underframe 12c is supported at its body bolsters 22c by legs 16c which stand upon the body bolsters 22b of the second underframe 12b. The second underframe 12b is supported at its body bolsters 22b at legs 16b which stand upon the body bolsters 22a of the lowermost underframe 12a. The lowermost underframe 12a is supported at its body bolsters 22a by legs 16a which stand on the ground surface G.

[0119] The legs 16 and body bolsters 22 are positioned directly vertically with respect to each other so as to collectively form four vertical columns 30. The four columns 30 support the weight of each underframe 12 and carry the load to the ground G on which the columns 30 stand. For example, the four body bolsters 22d of the top underframe 12d sit atop each of the columns 30 and such that the weight of the top underframe 12d is supported by each of the body bolsters and legs 16 that form the columns. In this way, whilst all body bolsters 22 (except the body bolsters 22d of the top underframe 12d) experience load from the weight of higher underframes 12, the rest of each underframe 12 is not subjected to load from a higher underframe 12. That is, load is transmitted only through the body bolsters 22 and not through other portions of the underframes 12.

[0120] The load experienced by some of the body bolsters 22 due to the weight of higher underframes is a compressive load by virtue of the body bolster 22 being sandwiched between two legs 16 (a higher leg 16 and a lower leg 16) of the columns 30. The body bolsters 22 are configured with relatively high compressive strength that tolerates the compressive load applied to the body bolsters 22 within columns 30. Advantageously, in the column configuration, the weight of a higher underframe 12 does not apply bending load to a lower underframe 12.

[0121] Still referring to Figure 2, an overhead lifting beam 32 is connected to the lowermost underframe 12a via four lifting tethers 34. The tethers 34 are secured at a connection 36 with longitudinal side beams comprising longitudinal clamp sills 37 of the lowermost underframe 12a. The underframe package 10 is thereby liftable as a single unit via the lifting beam 32 and tethers 34.

[0122] Turning to Figures 6 to 9, the upper end 16b of each leg 16 includes three mounting brackets 36 configured to secure the body bolsters 22 of the underframes 12 to the legs 16. The mounting brackets 36 have a clamp configuration with a clamp plate 37 connected to the leg upper end 16b via adjustable bolts 40 (two of which are labelled in Figure 7) and whereby tightening of the bolts 40 moves the clamp plate 37 downward toward the leg upper end 16b in order to clamp the body bolsters 22 and thereby mount the underframe 12 to the legs 16. Figure 9 shows two of the three mounting brackets 36 clamped upon the body bolster 22 (the third mounting bracket 36 being obscured in the Figure 9 perspective). In particular, the mounting brackets 36 clamp onto a lip 23 at a base of the body bolsters 22.

[0123] As best shown in Figure 6, the legs 16 include a square-shaped lower plate 42 at their lower end 16a, a square-shaped upper plate 44 at their upper end 16b and an elongate portion 46 extending between the lower and upper plates 42, 44. The upper plate 44 is located at the upper end 16b of the leg 16. The upper plate 44 is larger than the lower plate 42 in order to accommodate the mounting brackets 36 and the locating protrusion 19. As shown in Figure 9, the lower plate 42 has approximately the same length and width as the body bolsters 22. The larger upper plate 42 accommodates at its periphery the mounting brackets 36 and locating protrusion 19. The upper ends 16b of the legs 16 further include a rubber support pad 52 between the body bolsters 22 and the upper plate 44.

[0124] The elongate portion 46 of the legs 16 include four steel L-shaped portions 48 which comprise the four corners of the elongate portion 46. The elongate portion 46 is therefore generally hollow and with openings 49 provided between the L- sections 48. This configuration minimises weight as well as the materials required to produce the legs 16. The elongate portion 46 further includes several stiffening plates 50.

[0125] Turning to Figures 10 - 12, the underframe package 10 includes bindings for securing the underframes 12 to a higher or lower underframe 12 in the stacked arrangement. The bindings include coupler bindings 54 shown in Figures 10 and 11. Figure 10 illustrates a first end of the underframes 12 and in which the first end coupler shank 56 of the lowermost underframe 12a is connected to the first end coupler shank 56 of the second underframe 12b by a first binding 54-1 comprising a looped tether. The first end coupler shank 56 of the second underframe 12b is connected to the coupler shank 56 of the third underframe 12c by a second binding 54-2.

[0126] Figure 11 illustrates the opposite ends (i.e. the second ends) of the underframes 12 in the stacked arrangement. Similar to Figure 10, the second end coupler shank 58 of the lowermost underframe 12 is connected to the second end coupler shank 58 of the second underframe 12b by a binding comprising a looped tether 54-3.

[0127] Turning to Figure 12, clamp sill bindings 60 comprising looped tethers secure the clamp sills 37 of vertically adjacent underframes 12. A first tether 60-1 connects the longitudinal clamp sills 37a of the lowermost underframe 12a with the longitudinal clamp sills 37b of the second underframe 37b. A second tether 60-2 connects the longitudinal clamp sills 37b of the lowermost underframe 12b with the longitudinal clamp sills 37c of the third underframe 37c. A third tether 60-3 connects the longitudinal clamp sills 37c of the third underframe 12c with the longitudinal clamp sills 37d of the top underframe 37d.

[0128] In a form of the invention, the coupler bindings 54 comprise steel cable and the binding procedure involves placing protective rubber sheeting around the first and second end coupler shanks 56, 58 before passing the steel cable 54 around vertically adjacent shanks 56, 58 and then tightening by ratchet tightening devices.

[0129] Turning to Figure 13, there is illustrated a side wall package 62 which includes a side wall support arrangement comprising a side wall frame 64 and seven ore car side walls 66. The side walls 66 are arranged in a row 68 whereby the side walls 66 are each upstanding and side-by-side and parallel with respect to each other. The dimensions of the side wall row 68 are less than the dimensions of the side wall frame 64 such that the side wall row 68 is bounded at all sides by at least a portion of the side wall frame 64.

[0130] The identical side walls 66 in the side wall row 68 each include a pair of opposite end edges 84 in an upright orientation, a horizontal base edge 88 and a horizontal upper edge which comprise an upper cant rail 86.

[0131] As shown in Figure 14, the side wall package 62 is configured to be lifted by an overhead lifting beam 70 connected to the side wall frame 64 via lifting tethers 72. The tethers 72 are connected to openings 114 in stiffeners 73 (best shown in Figure 19) at the base of side uprights 90 which will be described in further detail below.

[0132] Turning to Figure 15, the side wall frame 64 is illustrated without the side wall row 68. The side wall frame 64 includes a rectangular base 65 comprising a pair of opposite longitudinal side members 74 and a pair of opposite end members 76. The frame 64 further includes four corner uprights 78 upstanding from the corners of the base 65. An upper end cross-member 80 extends between upper ends 82 of each pair of the corner uprights 78. The upper end cross-member 80 has an orientation parallel with the end members 76 of the base 65 and, in use, extends along upper corners of the seven side walls 66 in the side wall row 68 (as is shown in Figure 14). [0133] Still referring to Figure 15, the upper end cross-members 80 each include a row of detachably mounted projections comprising L-shaped brackets 82 for supporting the side walls 66. The row of brackets 82 provide a series of openings 83 between adjacent brackets for receiving an upper part of the side wall end edges 84. This is best shown in Figure 21 which a pair of the brackets 82 associated with each side wall 66. Each pair of brackets 82 is spaced apart to provide an opening which receives the side wall end edge 84 and, in particular, the top corner of one of the side walls 66.

[0134] During insertion and removal of the side walls 66, the brackets 82 are manually fitted and removed. In particular, a spreader lifting bar with clamps attached to the upper cant rail 86 of a side wall 66 may be used to load and unload each side wall 66. During the unloading procedure, the weight of the side wall is taken up by the lifting bar and the alignment of the spreader bar checked to ensure it is aligned vertically to the attached side wall 66. The brackets 82 associated with the attached side wall 66 are then removed. The side wall 66 is then lifted vertically until clear of the side wall frame 64. The same process is used to install the side walls into the side wall frame 64

[0135] The side wall frame 64 further includes three pairs of side uprights 90 upstanding from the longitudinal side members 74 of the base 65 and three top crossmembers 92 extending between upper ends of each pair of side uprights 90. As shown in Figure 13, the top cross-members 92 extend above the upper cant rails 86 of each of the side walls 66. Each the top cross-member 92 each includes a pair of opposite ends comprising flat portions 94 and a channel portion 96 extending between the flat portions 94. As shown in Figure 15, the channel portions 96 provide a pair of upstanding edges 108 at each end of each channel portion 96.

[0136] The base 65 further includes three base cross-members 98 vertically below the three top cross-members 92 and extending between the longitudinal side members 74. As best shown in Figure 18, the base cross-members 98 include seven recesses 100 spaced along the length of each base cross-member 98 by six pairs of divider plates 102. The recesses 100 are configured to receive a lower portion of the side walls 66 and in particular a lower portion of an elongate stiffening rib comprising a vertical stiffening stanchion 104 (welded to the side wall 66) and which is illustrated in Figure 20.

[0137] In the illustrated embodiment the divider plates 102 are shown as six pairs. In an alternative embodiment each pair may be replace by a single divider plate and wherein each base cross-member 98 includes six divider plates forming the seven recesses 100. In a further embodiment, the base cross members 98 may include a divider plate at their opposite ends which abuts the longitudinal side members 74. In this instance, the base cross-members 98 may include nine plates forming the seven recesses.

[0138] Figure 16 provides a plan view of the side wall frame 64 in which the left of the three top cross-members 92 is shown in place but the middle and right top crossmembers 92 are not shown in order to show the middle and right base crossmembers 98 which are positioned directly below the top cross-members 92. The top cross-members 92 are of larger width than the base cross-members 98.

[0139] Turning to Figure 17, the relative positioning of the base cross members 98 and top cross-members 92 facilitate a pair of side wall packages 62 to be vertically stacked in order to form a double stack 106 of side wall packages comprising a lower side wall package 62a and an upper side wall package 62b stacked atop the lower side wall package 62a. This is particular advantageous during sea freight to minimise occupation of sea freighter floor area or to maximise the number of components freighted on a given floor area.

[0140] Figure 17a is a perspective sectional view illustrating a base cross-member 98 of the upper side wall package 62b received in the channel portion 96 of a top cross-member 92 of the lower side wall package 62a. As noted, the top crossmembers 92 are provided with a larger width than the base cross-members 98 allowing for the base cross-members of the upper side wall package 62b to be lowered into the channel portions 96. The base side members 74 of the upper side wall package 62b are located upon the flat portions 94 of the lower side wall package 62a. This engagement resists relative movement between the upper and lower side wall packages 62a, 62b in both the longitudinal and lateral directions. [0141] In particular, relative longitudinal movement is resisted by virtue of the base cross-members 98 and top cross-members being perpendicular to the longitudinal axis of the side wall packages 62a, 62b. The base cross-members 98 of the upper package 62a are therefore unable to move along the longitudinal axis by virtue of their receipt within the channel portions 96. Furthermore, relative lateral movement between the upper and lower side wall packages 62a, 62b is resisted by the longitudinal side members 74 of the upper side wall package 62b abutting the upstanding edges 108 of the channel portions 96 of the lower side wall package 62a.

[0142] Turning to Figure 19, the base side members 74 may include strapping projections comprising upstanding rigid loops 110 to which straps 112 may be attached. As best shown in Figure 14, the side wall package 62 may further include three straps 112 extending across a top of the side wall row 68 and connecting to the rigid loops 110 on the side members 74. As best shown in Figure 19, a steel stiffener 73 is provided at the base of each side upright 90 and which includes the openings 114 for receiving a lifting tether to allow lifting of the side wall package 62 as shown in Figure 14.

[0143] Turning to Figure 22, there is illustrated an end wall package 116 which includes an end wall support arrangement comprising an end wall frame 118 and ten ore car end walls 120. The end walls 120 are each orientated horizontally (i.e. laid flat) and are positioned vertically with respect to each other in a vertical stack 122. The stack 122 has dimensions less than that of the end wall frame 118 such that the stack fits within the external dimensions of the frame 118. The stack 122 is bounded at all sides by one or more portions of the end wall frame 118.

[0144] The end walls 120 of the end wall package 116 each include a rib structure 124 on their exterior face 129. With reference to the uppermost rib structure 124-1 which is visible in Figure 22, each rib 124 includes a pair of longitudinal portions 128 extending the length of the end wall stack 122 and a lateral portion 130 extending perpendicularly to the longitudinal portions 128 The rib structure 124 further includes a longitudinal edge rib 172. In Figures 22, 25 and 26 the lateral portion 130 is shown extending partially across the width of the end wall stack 122. However, in other forms of the invention the lateral portion 130 may extend the entire length of the end wall stack 122 or until abutment with the longitudinal edge rib 172. [0145] The risk of damage during transport is further mitigated by orientating the inside faces 126 of the end walls 120 downwardly to protect the inside faces 126 against damage from objects falling onto the end wall package 116 during transport.

[0146] Returning to Figure 22, the end wall frame 118 includes a rectangular base 132 comprising a pair of longitudinal members 134 and a pair of end members 136. The end members 136 are each provided with a pair of upstanding strapping loops 138 to which a pair of longitudinal straps 140 are attached. Each longitudinal strap 140 extends along opposing vertical ends 148 of the end wall stack 122 and horizontally along the longitudinal portions 128 of the uppermost spacer 124-1. The longitudinal members 134 of the base 132 each include an upstanding strapping loop 142 to which a single lateral strap 144 is attached. The lateral strap 144 extends along opposing vertical sides 146 of the end wall stack 122 and extends horizontally and in a lateral direction along the lateral portion 130 of the uppermost spacer 124-1. The straps 140, 144 thereby secure the stack of end walls 120 and spacers 124 to the base 132.

[0147] Still referring to Figure 22, a protective elongate rubber strip of approximately 10mm thickness is located atop each of the spacer lateral portions 130. Elongate rubber sheets 127 are also provided between the base 132 and the lowermost end wall 120.

[0148] Turning to Figures 23 and 24, the end wall frame 118 is illustrated in isolation and in which the rectangular base 132 is shown with the pair of base longitudinal members 134 and the pair of base end members 136. The base 132 further includes three base cross-members 150 extending between the opposite longitudinal members 134 and located intermediate of the end members 136. In the illustrated embodiment the base cross-members 150 comprise C-section beams. The end wall frame 118 further includes two pairs of side uprights 152 upstanding from the base longitudinal members 134 with one side upright 152 in each pair upstanding from each base longitudinal member 134. The side uprights 152 bound the vertical sides 146 of the end wall stack 122 providing a degree of mechanical protection against impacts. [0149] The end wall frame 118 further includes two top cross-members 154 and with one of the top cross-members 154 extending between upper ends of each pair of side uprights 152. The top cross members 154 are orientated horizontally and extend laterally (i.e. perpendicular with a longitudinal axis of the end wall frame 118) between the side uprights 152. Each of the top cross-members 154 includes a pair of opposite ends comprising flat portions 156 and a channel portion 158 extending between the flat portions 156. As shown in Figure 23, the channel portions 158 provide a pair of upstanding edges 160 at each end of each channel portion 158.

[0150] The end wall frame 118 further includes an end upright 162 upstanding from each of the base end members 136. The end uprights 162 bound the vertical ends 148 of the end wall stack 122 providing a degree of mechanical protection against impacts. The end wall frame 118 further includes stiffeners 163 fitted to the bases of each of the end uprights 162 and side uprights 152.

[0151] Figure 25 illustrates the end wall package 116 connected to a lifting beam 164 via lifting tethers 166 which connect to openings 168 (best shown in Figure 24) in the four stiffeners 163 at the bases of the side uprights 152.

[0152] As will be appreciated from Figures 23 and 24, the channel portions 158 of the top cross members are directly vertically above the base cross-members 150. The channel portions 158 are of slightly larger width than the base cross-members 150. Turning to Figure 26, this configuration facilitates a pair of end wall packages 116 to be vertically stacked in order to form a double stack 170 of end wall packages comprising a lower end wall package 116a and an upper end wall package 116b stacked atop the lower end wall package 116a.

[0153] The upper and lower end wall packages 116a, 116b are engaged with one another in the same manner as is described above with respect to the double stack 106 of end wall packages. In particular, the base cross-members 150 of the upper end wall package 116b are seated in the channel portions 158 of the lower end wall package 116a. Longitudinal relative movement between the two packages 116a, 116b is resisted by virtue of the channel portions 158 and base cross-members 150 being orientated perpendicularly to the longitudinal direction. Lateral relative movement between the packages 116a, 116b is resisted by the longitudinal members channel portions 158 of the lower end wall package 116a.

[0154] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope of the present invention.

[0155] Where any or all of the terms "comprise", "comprises", "comprised" or "comprising" are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components.