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_
THE CHLORINE INSTITUTE
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Pamphlet 76
Guidelines for the Safe
Motor Vehicular
Transportation of Chlorine
Cylinders and Ton
Containers

Edition 6

September 2018
 Table of Contents

1. INTRODUCTION ................................................................................................................ 1
1.1 SCOPE .......................................................................................................................... 1
1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM............................................................... 1
1.3 DEFINITIONS AND ACRONYMS ......................................................................................... 1
1.4 DISCLAIMER .................................................................................................................. 2
1.5 APPROVAL .................................................................................................................... 3
1.6 REVISIONS .................................................................................................................... 3
1.7 REPRODUCTION ............................................................................................................ 3
2. EMERGENCY RESPONSE ................................................................................................ 4
2.1 CHLOREP® ................................................................................................................. 4
2.2 CHEMTREC® AND CANUTEC.................................................................................... 4
2.3 PERSONAL PROTECTIVE EQUIPMENT .............................................................................. 4
2.4 REPORTING OF RELEASE ............................................................................................... 4
2.5 EMERGENCY KITS .......................................................................................................... 5
3. REGULATIONS .................................................................................................................. 5
3.1 DOT REGULATIONS ....................................................................................................... 5
3.2 TSA RECOMMENDATIONS .............................................................................................. 6
3.3 EPA REGULATIONS ....................................................................................................... 6
3.4 OSHA REGULATIONS .................................................................................................... 6
3.5 CANADIAN REGULATIONS ............................................................................................... 6
4. TRAINING .......................................................................................................................... 7
4.1 GENERAL ...................................................................................................................... 7
4.2 MANDATORY TRAINING REQUIREMENTS .......................................................................... 7
5. TRANSPORTING 100 AND 150 LB. (45.4 AND 46 KG) CYLINDERS ............................... 8
5.1 CLOSED VAN TRUCKS/BOX TRAILERS ............................................................................. 8
5.2 OPEN TOP - TRUCKS/TRAILERS .....................................................................................13
5.3 CONSTRUCTION ............................................................................................................13
5.4 LIFT GATES ..................................................................................................................14
6. TRANSPORTING TON CONTAINERS .............................................................................15
6.1 OPEN TOP TRUCKS AND TRAILERS ................................................................................15
6.2 TON CONTAINER LOADING AND UNLOADING ...................................................................19
6.3 DOUBLE STACKING TON CONTAINERS............................................................................19
7. COMBINATION SHIPMENTS............................................................................................19
7.1 CYLINDER AND TON CONTAINERS ..................................................................................19
7.2 CHLORINE AND OTHER CHEMICAL SHIPMENTS ...............................................................20
7.3 COMMON CARRIERS .....................................................................................................20
7.4 HAZARDOUS MATERIALS SAFETY PERMIT ......................................................................21
7.5 SECURITY PLAN............................................................................................................21
7.6 PHMSA REGISTRATION ................................................................................................21
7.7 SHIPPING PAPERS ........................................................................................................22
7.8 PREVENTATIVE MAINTENANCE PROGRAM ......................................................................22
7.9 PERSONAL PROTECTIVE EQUIPMENT .............................................................................22

i
8. REFERENCES ..................................................................................................................23
8.1 CHLORINE INSTITUTE REFERENCES ...............................................................................23
8.2 DOT REGULATIONS ......................................................................................................24
8.3 TSA RECOMMENDATIONS .............................................................................................24
8.4 EPA REGULATIONS ......................................................................................................24
8.5 OSHA REGULATIONS ...................................................................................................24
8.6 CANADIAN REGULATIONS ..............................................................................................24
8.7 OTHER CHLORINE INSTITUTE PUBLICATIONS ..................................................................25
APPENDIX A – PAMPHLET 76 CHECKLIST...........................................................................26
DRAWINGS ..............................................................................................................................28
DRAWING 122: TON CONTAINER LIFTING BEAM .........................................................................29

ii
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 1

1. INTRODUCTION

1.1 SCOPE

The motor vehicular transportation of chlorine is extensively regulated by the U.S.

Department of Transportation (DOT) and Transport Canada (TC). This pamphlet is not
meant as a summary or substitute for those regulations. All persons transporting
chlorine or offering chlorine for transportation should be thoroughly familiar with all
applicable regulations.

1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM

The Chlorine Institute (CI) exists to support the chlor-alkali industry in advancing safe,
secure, environmentally compatible, and sustainable production, distribution, and use of
its mission chemicals 1.

Chlorine Institute members are committed to adopting CI’s safety and stewardship
initiatives, including pamphlets, checklists, and incident sharing, that will assist members
in achieving measurable improvement. For more information on the Institute’s
stewardship program, visit CI’s website at www.chlorineinstitute.org.

1.3 DEFINITIONS AND ACRONYMS

In this pamphlet the following meanings apply unless otherwise noted:

CANUTEC Canadian Transport Emergency Centre - Operated by Transport

Canada to assist emergency response personnel in handling
dangerous goods emergencies.

CEPA Canadian Environment Protection Act

CERCLA Comprehensive Environmental Response, Compensation and

Liability Act

CFR Code of Federal Regulations

CGSB Canadian General Standards Board

CHEMTREC® Chemical Transportation Emergency Center – An American

Chemistry Council division dedicated to assisting emergency
responders deal with incidents involving hazardous materials

1
CI’s mission chemicals: chlorine, sodium and potassium hydroxides, sodium hypochlorite, the
distribution of vinyl chloride monomer (VCM), and the distribution and use of hydrogen chloride.
2 PAMPHLET 76

CHLOREP® The Chlorine Emergency Plan - A chlor-alkali industry-wide program

formalized by the Chlorine Institute in 1972 to improve the speed
and effectiveness of response to chlorine emergencies in the United
States and Canada. Responsible for trained emergency teams from
chlorine producing, packaging and consuming plants on constant
24-hour alert to assist in handling potential or actual chlorine
emergencies. Typically activated through CHEMTREC or
CANUTEC.

CSA Canadian Standards Association

DOT Department of Transportation (U.S.)

E2 Plan Environmental Emergency Plan as defined in the Canadian E2

Regulations

E2 Regulations Canadian Environmental Emergency Regulations under Part 8 of

CEPA 1999

EPA Environmental Protection Agency (U.S.)

ERAP Emergency Response Assistance Plan per the Canadian

Transportation of Dangerous Goods (TDG) Regulations

FIFRA Federal Insecticide, Fungicide, and Rodenticide Act

FMCSA Federal Motor Carrier Safety Administration

HSSM Highway Security Sensitive Materials

Institute (CI) The Chlorine Institute

OSHA Occupational Safety and Health Administration under the U.S.

Department of Labor

PHMSA Pipeline and Hazardous Materials Safety Administration

TC Transport Canada

TDG Transportation of Dangerous Goods

TSA Transportation Security Administration

1.4 DISCLAIMER

The information in this pamphlet is drawn from sources believed to be reliable. The
Institute and its members, jointly and severally, make no guarantee and assume no
liability in connection with any of this information.

Moreover, it should not be assumed that every acceptable procedure is included or that
special circumstances may not warrant modified or an additional procedure.
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 3

The user should be aware that changing technology or regulations may require a change
in the recommendations herein. Appropriate steps should be taken to ensure that the
information is current when used. These recommendations should not be confused with
federal, state, provincial, municipal or insurance requirements, or with national safety
codes.

1.5 APPROVAL

The Institute's Transportation Issue Team approved Edition 6 of this pamphlet on

September 25, 2018.

1.6 REVISIONS

Suggestions for revisions should be directed to the Secretary of the Institute.

1.6.1 Significant Revisions in Current Edition

Revisions to Edition 6 of this pamphlet include:

• Enhanced guidance on emergency response (Section 2);

• Updated information on regulations (Section 3) and required training (Section

4).

• Clarified guidance regarding decking, cylinder containment in vans and box

trailers, material of construction and design of containment method (Section
5.1.1 and 5.1.4);

• Introduced new sub-section on cylinder securement by using straps (Section

5.3.2);

• Revised language regarding lift gates (Section 5.4);

• Added recommendations regarding containment of ton container on open

trucks/trailers (Section 6.1.2);

• Modified some language on ton container loading/unloading (Section 6.2);

and

• Minor edits throughout.

1.7 REPRODUCTION

The contents of this pamphlet are not to be copied for publication, in whole or in part,
without prior Institute permission.
4 PAMPHLET 76

2. EMERGENCY RESPONSE

2.1 CHLOREP®

The Chlorine Emergency Plan (CHLOREP) is an industry-wide program established by

the Institute to improve the speed and effectiveness of response to chlorine emergencies
in the United States and Canada.

Under this plan the United States and Canada have been divided into regional sectors
where chlorine emergency teams from producing, packager, and consuming plants are
on constant alert on a 24-hour basis, to handle threatened or actual chlorine leaks.
During a chlorine emergency, any carrier, customer, or civil authority can obtain basic
emergency information and be put in contact with the closest CHLOREP team by
phoning CHEMTREC/CANUTEC (See Section 2.2).

2.2 CHEMTREC® AND CANUTEC

For transportation-related incidents in the U.S., one should utilize CHEMTREC, the
Chemical Transportation Emergency Center in Falls Church, VA, as the dispatch
agency. CHEMTREC operates around-the-clock, 24 hours-a-day, seven days-a-week to
receive direct-dial, toll-free calls from any point in the United States and Canada at 1-
800-424-9300 (703-527-3887 for all other calls). CHEMTREC provides immediate
advice for those at the scene of an emergency, then, if the emergency involves chlorine,
promptly contacts the designated CHLOREP team, the shipper and others as required.
Registration with CHEMTREC is provided through the American Chemistry Council. In
Canada, one should utilize CANUTEC, the Canadian Transport Emergency Centre in
Ottawa as the dispatch agency. Their telephone number is 613-996-6666 (call collect).
CANUTEC, administered by TC, operates in a similar manner to CHEMTREC.

2.3 PERSONAL PROTECTIVE EQUIPMENT

Chlorine Institute Pamphlet 65 (8.1) provides information on personal protective

equipment for chlorine.

2.4 REPORTING OF RELEASE

Chlorine is identified as a hazardous substance in Table 302.4 – List of Hazardous

Substances and Reportable Quantities of 40 CFR 302.4 (8.2.1). The Comprehensive
Environmental Response, Compensation and Liability Act of 1980 (CERCLA) requires
immediate notification of a release equal to or in excess of the reportable quantity. The
reportable quantity of chlorine is 10 lbs. (4.54 kg). Should a reportable release occur in
the U.S., the law requires the National Response Center (1-800-424-8802 or
http://www.nrc.uscg.mil) be notified immediately.

The U.S. DOT requires an immediate notification by telephone of certain hazardous

materials transportation incidents (49 CFR 171.15) and a written report (within 30 days)
using the DOT Form F 5800.1 “Hazardous Materials Report” for certain incidents
including all those requiring an immediate notification (49 CFR 171.16) (14.2). Any
release of hazardous materials during any mode of transportation (i.e., including
temporary storage, in transit on the highway, transloading, or during on-site loading or
unloading operations when a carrier employee is present).
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 5

(See 49 CFR 171.15 and 171.16 for details) (8.2.1).

In Canada appropriate provincial response authorities must be immediately advised of a

chlorine release of any quantity.

State, provincial and local laws may require reporting to the appropriate state and/or
local environmental agencies.

2.5 EMERGENCY KITS

Chlorine Institute Emergency Kits and cylinder recovery vessels are designed to contain
most leaks which may be encountered from chlorine containers. The following kits and
recovery vessels are available:

• Kit A - for 100 lb. and 150 lb. (45.4 kg and 68.0 kg) cylinders

• Kit B - for ton containers

• Recovery vessels for cylinders

Guidelines for the use of the emergency kits and recovery vessel may be found in CI
pamphlets titled Chlorine Institute Emergency Kit "A" for 100 lb. and 150 lb. (45.4 kg and
68.0 kg) Chlorine Cylinders, Chlorine Institute Emergency Kit "B" for Chlorine Ton
Containers, and Chlorine Institute Recovery Vessel for 100 lb. and 150 lb. (45.4 kg and
68.0 kg) Chlorine Cylinders, and their respective videos (8.1).

It is a violation of the Hazardous Materials regulations to ship any container that is

leaking or may experience leakage under conditions normally experienced during
transportation, however the DOT allows the shipment of damaged or leaking chlorine
cylinders and ton containers under certain conditions. Each shipper or carrier must
become familiar with these requirements and how they apply to their specific operation.

Information regarding one-way transport of a leaking chlorine cylinder can be found in 49

CFR Part 173.3(d) and 173.3(e) (8.2.1). These paragraphs allow the transport of a
recovery vessel (or “salvage cylinder”), A-Kit, and B-Kit to transport a damaged or
leaking 150 lb. (68.0 kg) chlorine cylinder or ton container in certain situations. Details
include construction, marking and labeling requirements, shipping papers and cleaning
the cylinder after use.

3. REGULATIONS

3.1 DOT REGULATIONS

DOT's Pipeline and Hazardous Materials Safety Administration (PHMSA) and Federal
Motor Carrier Safety Administration (FMCSA) regulate the acceptance and
transportation of hazardous materials by highway, including chlorine, in the U.S.
PHMSA's Hazardous Materials Regulations (HMR) are found in 49 CFR Parts 171 to
180 (8.2.1). These parts include the classification of materials, general shipping
requirements, methods for hazard communication like marking, labeling, and placarding.
6 PAMPHLET 76

Because chlorine is a hazardous material, it is imperative that personnel involved in any

aspect of handling, packaging, and/or transportation of chlorine are knowledgeable of
the regulatory requirements pertaining to chlorine. FMCSA’s Motor Carrier Safety
regulations are found in 49 CFR parts 40, 380, 382, 383, 387, 390, 391-397, 399, and
Appendix G (8.2.1). These regulations cover topics such as the action of the drivers and
maintenance of the vehicles.

3.2 TSA RECOMMENDATIONS

The U.S. Department of Homeland Security’s (DHS’s) Transportation Security

Administration (TSA) has established security action items that motor carriers should
consider for the development, implementation, and revision of their security plans for
Tier 1 and Tier 2 highway security-sensitive materials (HSSM). These action items are
voluntary to allow highway motor carriers to adopt measures best suited for their
particular practices. The security action items are divided into four categories:

1. General Security

2. Personnel Security

3. Unauthorized Access

4. En Route Security

These security action items allow for flexibility based upon the assessed vulnerability of
a particular process or operation. See TSA’s memo to highway and motor carrier
security partners dated June 26, 2008, as well as the action memo for modification dated
May 20, 2009, for more details (8.3.1).

3.3 EPA REGULATIONS

In the United States, when chlorine is used for disinfection of drinking water, wastewater
and swimming pools it is considered to be a fungicide and is subject to EPA regulations
issued under the Federal Insecticide, Fungicide and Rodenticide Act (FIFRA). The EPA
regulations, found in 40 CFR Subchapter E Part 156, require shipper registration with
EPA and appropriate labeling (8.4).

3.4 OSHA REGULATIONS

The OSHA’s occupational safety and health standards are found in Title 29 CFR Part
1910. Title 29 CFR regulates material handling and storage, process safety
management, the emergency response to hazardous substance releases and personal
protective equipment (8.5).

3.5 CANADIAN REGULATIONS

Canadian Regulations are covered by Transport Canada in the Transportation of

Dangerous Goods (TDG) Act and Regulations, which parallel the DOT requirements in
most respects.
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 7

There are 16 parts to the regulations which cover such items as Interpretations, General
Provisions, Classification, Documentation, Dangerous Goods Safety Marks, Means of
Containment, Training, Emergency Response Plan, and Accident Release and Imminent
Accidental Release Report Requirements. These regulations include, by reference,
various standards published by agencies such as the Canadian Standards Association
(CSA) and the Canadian General Standards Board (CGSB). Shippers of cylinders and
ton containers need to be aware there are three (3) schedules to the regulations.
Shippers must become familiar with these regulations and how they could affect their
operation. The Transport of Dangerous Goods Act is the authority under which
dangerous goods are regulated. The Act supersedes the Regulations.

For the transportation of chlorine in ton containers within Canada, a Transport Canada
approved Emergency Response Assistance Plan (ERAP) is also required. The
requirements and approval process are detailed in Part 7 of the TDG Regulations (8.6.1)

In Canada, the Canadian Environmental Protection Act, 1999 (CEPA 1999), should also
be reviewed for specific federal environmental requirements. Chlorine is listed in
Schedule 1 of Canada’s Environmental Emergency Regulations (E2 Regulations). If your
facility owns or has the charge, management or control of a Schedule 1 substance
above the threshold quantities, your facility is required to have an E2 Plan. Information
for the preparation, implementation, government submission and testing of an E2 Plan is
available through Environment Canada (8.6.2).

Requirements for the safe motor vehicular transportation of chlorine in cylinders and ton
containers can be found in Parts 1-16 of the regulation (8.6.1).

4. TRAINING

4.1 GENERAL

Every person working with chlorine must be trained to ensure safe handling of the
product during packaging, storage, transportation, and should be familiar with their
company’s emergency reporting procedures.

4.2 MANDATORY TRAINING REQUIREMENTS

Personnel involved in the loading, unloading, inspection, or shipping of hazardous

materials must be properly trained. Mandatory training requirements have been
established by DOT and Transport Canada. DOT hazmat employee training
requirements are found in 49 CFR 172.700 and 174.704 (8.2.1) and include:

• General awareness

• Function-specific training

• Safety training

• Security Awareness Training

• In-Depth Security Training

8 PAMPHLET 76

• OSHA and EPA training

• Training record retention

Driver training requirements may be found in 49 CFR 177.800 and 177.816 (8.2.1) and
include, but are not limited to:

• Pre-trip driver inspections

• Use of vehicle controls

• Operation of vehicle

• Attendance and parking

• Loading and unloading

• Cargo compatibility

• Package handling

• Load securement

Additional driver requirements may be found in 49 CFR Parts 383, 386 and 390-397
(8.2.1). For Canadian training requirements refer to Section 3.5 of the TDG (8.6.1).

5. TRANSPORTING 100 AND 150 LB. (45.4 AND 46 KG) CYLINDERS

5.1 CLOSED VAN TRUCKS/BOX TRAILERS

Closed van trucks and box trailers are commonly used for shipping chlorine cylinders.
When transporting chlorine cylinders via closed van trucks or box trailers, it is
recommended the trailers have ventilation openings in the front and rear of the trailer.
This creates a minimal forced airflow through the trailer. No package marked poison,
poison gas or poison inhalation hazard may be loaded into a motor vehicle carrying any
type of foodstuff (human or animal), nor into the driver’s compartment (including sleeper
berth) of a motor vehicle (see 49 CFR 177.841) (8.2.1).

Modifying standard equipment to improve the safe transportation of chlorine cylinders is

recommended. Among these modifications are the following:

5.1.1 Decking

Carriers transporting chlorine in cylinder and ton containers need to evaluate the decking
material that will best serve their needs. Both wood/composite and metal decks each
have their pros and cons. Metal decks, such as metal diamond plate decking, are
resistant to rotting, reduce the risk of fire, and have minimal maintenance requirements.
Wood or composite decking, if properly maintained, can provide a long-lasting surface
that presents less of a slip hazard when wet.
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 9

When the carrier selects the material of construction that best meets their needs the
floor should have the minimum strength needed to safely carrier the cylinders and or the
ton containers.

For metal diamond plate steel, a minimum thickness of 5/16 inch (0.79cm) or a metal of
equivalent strength should be used unless applied over a wood deck, in which case 1/4
inch (0.64cm) of diamond plate steel or a metal of equivalent strength should be used.
For wood decking in van trucks or box trailers a wood or composite decking with the
same strength as 1 1/8 inch (2.9cm) oak flooring laid over structural steel crossmembers.

For wood or composite decking used in open or flatbed trailers, 1 3/4 inch (4.5cm) oak
shiplap flooring or a material of equivalent strength should be used.

5.1.2 Bulkhead Attachments

Steel rings can be used to anchor strapping and chains for securing the cylinder load.
These rings should be attached to the van truck or box trailer wall by bolting through the
side walls (Figure 5.1).

The rings should be located at two levels, approximately 15 inches and 36 inches (38.1
cm and 91.4 cm), from the floor. (If compressed gas cylinders with different heights are
transported in the van truck or box trailer, additional levels of rings may be required).

Figure 5.1
Steel rings used for securing cylinders to van truck wall
10 PAMPHLET 76

5.1.3 Bulkhead Tracks

Logistic rail (wall track or E track) is widely used with patented fasteners as part of
containment systems for shipping chlorine cylinders. Rail at levels of approximately 15
inches and 36 inches (38.1 cm and 91.4 cm) off the truck bed floor should be installed
and fastened to structural members of the van truck or box trailer walls (Figure 5.2).

Figure 5.2
Straps and logistic rail for securing cylinders

5.1.4 Cylinder Containment in Vans and Box Trailers

Some suggested methods of containing chlorine cylinders in van trucks or box trailers
employ load bars (with a logistic rail system) or nylon strapping (with logistic rails or wall
rings) (Figures 5.1 and 5.2).

Carriers need to determine which securement system will prevent relative motion
between the cylinders that could possibly damage, compromise the integrity, or cause a
release of chlorine from the container. (See 49 CFR 177.834(a) and PHMSA
Interpretation #14-0230) (8.2).
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 11

Figure 5.3
Load bars and logistic rail for securing cylinders

Nylon straps can be used to augment this method. Patented systems using load bars
are available.

The strength rating of the nylon strap binding should be at least one half the weight of
the aggregate product to be secured (49 CFR 393.106(d)) (8.2.1).

For example, if 10 chlorine cylinders are transported with an average weight of 250 lbs.
(113.4 kg) each resulting in an aggregate weight of 2500 lbs. (1134.0 kg), then the
securement strap used should be rated to at least 1250 lbs. (567.0 kg). Nylon straps with
a 3000 lbs. (1360.1 kg) minimum test rating are commonly used for containing nested
clusters of chlorine cylinders along the van truck or box trailer wall. If more than 10
cylinders are to be contained in a cluster, higher strength rated straps should be used.
The nylon strap binding should be applied at the 15 inch and 36 inch (38.1 cm and 91.4
cm) levels around the cylinders. A ratchet buckle is one suggested method for
tightening the straps. Care must be taken if chains are used for containing chlorine
cylinders in vans or closed trailers since the binder often requires excessive force to
close and release; strain can pull out the wall rings or buckle the walls.

Nesting is a method of securing cylinders in a tight mass using a contiguous three-point

contact system where all cylinders in the group have at least three points of contact with
other cylinders, walls, or bracing. Nested cylinders have three contact points and are
considered to be more stable in this configuration. See Figure 5.4.
12 PAMPHLET 76

Cylinders Aligned, Nested Cylinders

but not Nested

Figure 5.4
Nested Versus Non-Nested Cylinders

Cylinders secured to cages or other similar securement devices offer a safe, secure
method of shipping chlorine cylinders if the proper loading and unloading equipment
(e.g. forklift trucks, loading docks) are available at the shipping and delivery points.
Special caged pallets, capable of holding 12 to 16 cylinders, normally constructed of
metal can be used when the truck bed construction allows. Reinforcement of the bed
may be required to handle the loaded pallets. Provision must be made for securing
cylinders to cages that are partially full to prevent movement while in transit. (See 49
CFR 393.100) (8.2.1)

When used in transportation, provisions must be made for securing the cages to the
truck or trailer bed. A typical cage may hold 16 chlorine cylinders (Figure 5.5).

Figure 5.5
Palletizing cylinders
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 13

5.2 OPEN TOP - TRUCKS/TRAILERS

Another frequently used method of transporting chlorine cylinders over the road is by
stake body trucks and trailers.

Figure 5.6
Chains used for securing cylinders in stake body trailers

5.3 CONSTRUCTION

The decking construction recommendations for these units are covered in Section 5.1.1.
In the absence of the van truck or box trailer walls, vertical stakes and horizontal
crossbars constructed of tubular steel or a material of equivalent strength must be used
for the sides and ends. The 36 inch (91.4 cm) high vertical stakes and crossbars should
be placed at heights of 15 inches and 36 inches (38.1cm and 91.4cm) above the decking
for standard cylinders (crossbar heights should vary depending on the size of the
cylinder being transported) and secured in order to prevent movement of the panel
during transportation. These crossbars can be integrated with a logistic rail (load bar)
system. (If solid bulkheads are used in lieu of stakes, a minimum height of 42 inches
(1.07 m) is recommended.)

5.3.1 Cylinder Securement in Open-Box Trucks/Trailers (Using Chains)

If chains are used to secure cylinders in open trucks/trailers, they must have sufficient
working load-limit, and the strength of load binders must be equal to or greater than the
minimum strength specified for the chains (49 CFR 393.102) (8.2.1). Chains also can be
used in combination with load bars to secure cylinders.

The recommendation in Section 5.1.4 with regard to nested cylinders and the use of
pallets also applies to open trucks and trailers.
14 PAMPHLET 76

Secured containment racks can also be used.

5.3.2 Cylinder Securement in Open-Box Trucks/Trailers (Using Straps)

If straps are used to secure cylinders in open trucks/trailers, they must have sufficient
working load limit, and may also be used in combination with load bars to secure
cylinders (8.2.1).

The recommendation in Section 5.1.4 with regard to nested cylinders and the use of
pallets also applies to open trucks and trailers. Secured containment racks can also be
used.

5.4 LIFT GATES

Trucks and trailers used for transporting chlorine cylinders may be equipped with
electric or hydraulic lift gates for loading and unloading to ground level.

The selection of lift gates is based on preference and service with mounting either on the
side or rear of the trailer bed. However, it is important to observe the weight limitation of
the unit installed. The manufacturers recommended maintenance should be followed at
a minimum. Climatic conditions should be considered when determining the frequency
of lift gate preventive maintenance service.

Figure 5.7
Ground level loading & unloading cylinders

Horizontal loading of cylinders is not recommended because a valve leak when a

cylinder is in the horizontal position may leak liquid chlorine.
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 15

6. TRANSPORTING TON CONTAINERS

6.1 OPEN TOP TRUCKS AND TRAILERS

Although it is recognized that large quantities of chlorine in ton containers are

transported in closed van trucks and box trailers in North America (e.g. containerized
export shipments), most ton containers are moved over the road in open top trailers. On
the occasion that ton containers are transported by closed van trucks or box trailers, it is
recommended the trailers have ventilation openings in the front and rear. This creates a
minimal forced airflow through the trailer.

No package marked poison, poison gas, or poison inhalation hazard may be loaded into
a motor vehicle carrying any type of foodstuff (human or animal), nor into the driver’s
compartment (including sleeper berth) of a motor vehicle (see 49 CFR 177.841) (8.2.1).

It is beyond the scope of this pamphlet to detail the requirements for the running gear,
such as tandem axles, computerized brakes, etc. The selection of equipment of this
type is dictated by federal, state, and provincial regulations. NOTE: Care must be taken
to secure labels in open top vehicles. Likewise, the weight limitations may vary from
state to state while Canadian limits exceed those in the United States.

6.1.1 Decking

Recommendations for floor decking are covered in Section 5.1.1. Specialized unloading
systems used on trailers dedicated to ton container transportation service, such as the
automatic unloading units, are built either with or without floor decking (See Section
6.1.3).

6.1.2 Containment of Ton Containers on Open Top Trucks and Trailers

Except for self-unloading trailers, the need to roll the containers to the rear of the trailer
bed prevents the use of fixed chocks or cradles for each container. DOT regulates
securement systems, including the number and strength of chains needed to secure
cylinders and ton containers in 49 CFR 393.102 (8.2.1). The rule states that the working
load limit of the tie-down assemblies used to secure an article in any direction must be at
least one half the weight of the aggregate product and containers. Different sizes and
numbers of chains are needed to secure various numbers and tare weights of ton
containers. Refer to the table in 49 CFR 393.108 for various working load limits (8.2.1).

For the purpose of this pamphlet, the most typical or common methods of securing
cylinders and ton containers are described herein, although other methods may be used
in industry and are acceptable methods of securing ton containers. Before establishing
a securement method, it is important to note that ton containers can have a full loaded
weight of approximately 3,500 lbs. (1587.57 kg). When securing ton containers,
securement measure must meet the standards specified in DOT regulations 49 CFR 393
(8.2.1).

Containers that are likely to roll during shipment must be restrained by chocks, wedges,
cradles or other equivalent means to prevent rolling (see 49 CFR 393.106(c)) (8.2.1)
(See Figure 6.1).
16 PAMPHLET 76

If a front bulkhead is used, it should be designed, installed and maintained in

accordance with the working load limits as specified in 49 CFR 393.102 (8.2.1).

Figure 6.1
Ton container blocking

Figure 6.2
Front bulkhead reinforcement for ton containers

Chains and straps should be inspected before each use. The following items should be
looked at:

• Wear

• Nicks

• Cracks

• Breaks

• Gouges

• Throat size of hooks

 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 17

• Chains must move freely with adjacent hooks

• Bend

• Stretch

• Cuts

• Fraying

When transporting by flatbed trailers, side rails or other devices are commonly used for
proper bracing to prevent lateral movement of the ton containers (see 49 CFR
393.102(c)(2)) (8.2.1). Square, tubular construction of the side rails and cross members
is specified and detailed in Section 5.3. Rear roll-off protection must be provided. A
reinforced, removable guard rail or a 15 inch (38.1 cm) high contour fitting steel chock-
anchored behind the rear-most container to the truck bed with pins or chains is an
effective restraint.

Figure 6.3
“C” clamp on two end ton containers of truck load

There are a number of trailers operated in service which have equipment mounted on
the trailer to load and unload ton containers (Figure 6.4). Fixed, mounted, hydraulic,
telescoping booms, traveling booms, and overhead, mono-railed chain hoists are in this
category. Proper training in the operation of these trucks is essential. If overextended, it
can cause a lack of stability to the trailer and/or damage to the crane.
18 PAMPHLET 76

Figure 6.4
Telescopic boom mounted on ton container trailer

One method of securing ton containers on this type of equipment is with individual
cradles and lockdown devices (Figure 6.5).

Figure 6.5
Ton container lockdown devices

Alternate methods include use of individual stationary chocks and 3/8 inch (0.95 cm)
proof-coil chains 35,000 lbs. (15,876 kg) minimum breaking strength for up to six ton
containers) with load binders to secure the tons to the bed. If more than six containers
are to be secured with one set of chains, a higher strength chain must be considered.
See 49 CFR 393.106 and 393.108 for more details on various working load limit
requirements (8.2.1). Where individual cradles and lockdown devices are not used, the
recommendations stated earlier in this section for side rails, front bulkhead, and rear roll-
off protection apply.
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 19

This pamphlet will make no attempt to cover the safety considerations in operating
specialized self-loading and unloading equipment for chlorine ton containers that are
mounted on the trailers. Following the manufacturer’s instructions is important.

6.2 TON CONTAINER LOADING AND UNLOADING

The use of lifting beams either on the overhead cranes, traveling electric hoists, or forklift
trucks is frequently employed by shippers and customers for loading and unloading ton
containers. Proper design of the lifting beam is essential. A typical design is provided in
CI Drawing 122 (8.1). A majority of packaging plants use forklift trucks for handling ton
containers. Some use special attachments designed specifically for ton containers or
extra-long forks with tilt capabilities. Extreme care must be exercised when operating
forklift trucks in ton container service. Among considerations are:

• roll-off restraint on forks

• must be rated at a 4,000 lb. (1,814 kg) minimum lifting capacity

• side shifters for forks

• use only on smooth surfaces

• avoid speeding

• avoid sharp turns

• proper spacing of forks

Trailers and trucks may be equipped with electric or hydraulic tailgates. While raising or
lowering the tailgate a positive means of preventing the ton container from rolling off
must be provided. Proper training of personnel to guard against strains, toe injuries, etc.
is important when moving ton containers manually. Devices such as a chime wrench
may be used to facilitate moving ton containers. Overextending fasteners may cause
them to flip open and injure the operators.

6.3 DOUBLE STACKING TON CONTAINERS

Double stacking of full ton containers on trailers is not recommended unless the trailers
are equipped with specially designed cradles and lockdown devices. Empty ton
containers may be double stacked on trailers provided adequate securement is provided
to prevent movement in transit (some suggested methods are: clamped to bottom row,
extended side rails).

7. COMBINATION SHIPMENTS

7.1 CYLINDER AND TON CONTAINERS

Chlorine cylinders and ton containers are frequently shipped together as combination
loads.
20 PAMPHLET 76

When shipping chlorine cylinders and ton containers in combination careful thought must
be given to the securement requirements detailed in Sections 5 and 6 of this pamphlet.

7.2 CHLORINE AND OTHER CHEMICAL SHIPMENTS

Shipments of chlorine cylinders and one-ton containers are sometimes combined with
other hazardous and non-hazardous chemicals. The “Segregation Table for Hazardous
Materials” located in 49 CFR 177.848 deals with the separation and segregation of
hazardous materials (8.2.1). This table and the accompanying instructions give clear
guidance on whether certain classes or divisions of hazardous materials can be loaded
together, and what restrictions, if any, apply when they are loaded together.

DOT has provided guidance in regulatory interpretation responses, particularly

Reference Numbers 08-0143 and 08-0201 (8.2.3 and 8.2.4), to help shippers comply
with the regulations when two materials must be separated in such a way that “in the
event of leakage from packages under conditions normally incident to transportation,
commingling of hazardous materials would not occur.” These interpretations include
guidance on placing barriers between packages inside of the transport vehicle, as long
as they are sufficient to keep the materials from commingling, including:

• impediments

• obstructions

• dividers

• packages of non-hazardous materials

• non-reactive freight

• non-permeable barriers

• non-combustible, non-reactive absorbents

• intervening space

Although the regulations do not specify a minimum segregation distance, separation by

a distance of 4 feet (1.21 m) in all directions is considered acceptable by the DOT. The
DOT has made it clear that the integrity of the container is not considered an acceptable
barrier. Canadian Regulations pertaining to segregation can be found in the
Transportation of Dangerous Goods Act and Regulations (See Section 3.5).

7.3 COMMON CARRIERS

The use of common carriers for transporting cylinders and ton containers of chlorine
requires careful consideration. The shipper must be certain that any and all employees
(drivers, warehouse and others) involved in any way with the preparation for
transportation of hazardous materials are properly trained, and the training is
documented per DOT requirements. In an emergency the driver may become involved
in the implementation of emergency plans. Drivers need to be familiar with the details of
such a plan.
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 21

The shipper must confirm that the carrier uses only drivers with valid commercial driver’s
licenses with the required hazardous materials endorsement. It is recommended that
shippers use some form of carrier selection checklist to evaluate the use of current and
new carriers.

7.4 HAZARDOUS MATERIALS SAFETY PERMIT

Regulations require that any carrier who transports (among other hazardous
commodities) a shipment of Hazard Zone B materials in a bulk packaging (capacity
greater than 119 gallons (450 L)) must apply for and be awarded a Hazardous Materials
Safety Permit. Criteria for the permit is maintaining a Satisfactory Rating and can be
found in the DOT’s Federal Motor Carrier Safety Administration’s (FMCSA’s) regulations
under 49 CFR Part 385 (8.2.1). As chlorine is a Hazard Zone B material and ton
containers have a water capacity greater than 119 gallons (450 L), any carrier
transporting chlorine must be in possession of this document.

Carriers transporting materials that require such a permit must develop a

communications log where the motor carrier is advised by the driver that the shipment
arrived as scheduled. Logs must be maintained for a period of six months, in
accordance with 49 CFR 385.415(c)(1) (8.2.1).

7.5 SECURITY PLAN

Regulations require that hazardous materials carriers develop and institute a

Transportation Security Plan as described in 49 CFR Part 172 Subpart I (8.2.1). At a
minimum, the security plan must include the following elements: personnel security,
unauthorized access and en route security. When developing these plans, CI’s Security
Management Plan for the Transportation and On-Site Storage and Use of Chlorine
Cylinders, Ton Containers and Cargo Tanks should be considered (provided to CI
members upon request). TSA has issued recommendations to help carriers develop,
implement, and revise their security plans (see Section 3.2).

All hazmat employees must receive training on the contents of the carrier’s plan (49 CFR
172.704) (8.2.1). As the carrier plan is considered a safety sensitive document it is not
appropriate to request a copy of this plan from your carrier. Rather you should obtain
certification by the carrier that the plan is in place and conforms with all applicable
requirements.

Regulations require that hazardous materials carriers develop and institute a Security
Awareness Training program as described in 49 CFR Part 172 Subpart H (8.2.1). All
hazmat employees must receive this training. New hazmat employees must obtain this
training within 90 days after employment.

7.6 PHMSA REGISTRATION

All carriers transporting hazardous materials must register with PHMSA (49 CFR Part
107 Subpart G) (8.2.1). Evidence of this registration must be carried in the transport.
22 PAMPHLET 76

7.7 SHIPPING PAPERS

In order to relinquish a parcel of any hazardous material, the shipper must prepare and
forward, along with the commodity, a shipping paper that complies fully with 49 CFR
177.817 (8.2.1). A 24-hour emergency phone number, along with the name of the entity
(i.e. shipper, CHEMTREC/CANUTEC), contract number or other unique identifier
assigned by an emergency response information provider, is required on the shipping
papers in a manner that is clearly visible so that it is quick and easy to find (49 CFR
172.604) (8.2.1).

7.8 PREVENTATIVE MAINTENANCE PROGRAM

It is recommended that all equipment used in handling chlorine cylinders and containers
be part of a preventive maintenance program. This program should include procedures
and inspections specific to the equipment used. Typical equipment used in the handling
of chlorine cylinders and containers include, but are not limited to, equipment such as
forklifts, cranes, pallet jacks, and the like.

It is common practice that forms and/or checklists be used to document compliance with
company policy and equipment manufacturer recommendations. Carriers are
encouraged to develop their own forms/checklists based on their own company policies
and operations.

7.9 PERSONAL PROTECTIVE EQUIPMENT

Exposure to chlorine can occur whenever chlorine is handled. It is recommended that

drivers transporting chlorine cylinders or ton containers have at least a minimum level of
protection in cases of chlorine emergencies. For selection considerations, as well as
other requirements, please refer to CI Pamphlet 65 (8.1).
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 23

8. REFERENCES

8.1 CHLORINE INSTITUTE REFERENCES

The following publications are specifically referenced in CI Pamphlet 76. The latest
editions of CI publications may be obtained at http://www.chlorineinstitute.org.

Pamphlet
Title
& Video

65 Personal Protective Equipment for Chlor-Alkali Chemicals; Ed. 6,

Pamphlet 65; The Chlorine Institute: Arlington, VA, 2015.

IB/A Instruction Booklet: Chlorine Institute Emergency Kit “A” for 100 lb.
and 150 lb. Chlorine Cylinders; Ed. 12, Rev 2, Pamphlet IB/A; The
Chlorine Institute: Arlington, VA, 2014.

IB/B Instruction Booklet: Chlorine Institute Emergency Kit “B” for Chlorine
Ton Containers; Ed. 11, Rev 1, Pamphlet IB/B; The Chlorine Institute:
Arlington, VA, 2014.

IB/RV Instruction Booklet: Chlorine Institute Recovery Vessel for 100 lb.
and 150 lb. Chlorine Cylinders; Ed. 2, Pamphlet IB/RV; The Chlorine
Institute: Arlington, VA, 2009.

A-Video The Chlorine Institute Emergency Kit “A” and Recovery Vessel
Instructional Video, A-Video; Ed. 4, The Chlorine Institute: Arlington,
VA, 2014.

B-Video How to use the Chlorine Institute Emergency Kit “B” for Chlorine Ton
Containers; Ed. 3, B-Video; The Chlorine Institute: Arlington, VA,
2014.
Ton Container Lifting Beam, Drawing; DWG 122-2; The Chlorine
DWG 122
Institute: Arlington, VA, 1993.
24 PAMPHLET 76

8.2 DOT REGULATIONS

8.2.1 Code of Federal Regulations. Title 49. Parts 100-399. Office of the Federal Register
National Archives and Records Administration. U.S. Government Printing Office:
Washington, DC, (revised annually).

8.2.2 North American Emergency Response Guidebook. Office of Outreach, Engagement,

and Grants, PHH-50, Pipeline and Hazardous Materials Safety Administration, U.S.
Department of Transportation: Washington, DC, 2012.

8.2.3 Interpretation #08-0143. Office of Hazardous Materials Standards (PHH-10),

(https://www.phmsa.dot.gov/regulations/title49/interp/08-0143), Pipeline and Hazardous
Materials Safety Administration, U.S. Department of Transportation: Washington, DC,
2008.

8.2.4 Interpretation #08-0201. Office of Hazardous Materials Standards (PHH-10),

(https://www.phmsa.dot.gov/regulations/title49/interp/08-0201), Pipeline and Hazardous
Materials Safety Administration, U.S. Department of Transportation: Washington, DC,
2008.

8.2.5 Interpretation #14-0230. Office of Hazardous Materials Standards (PHH-10),

(https://www.phmsa.dot.gov/regulations/title49/interp/14-0230), Pipeline and Hazardous
Materials Safety Administration, U.S. Department of Transportation: Washington, DC,
2015.

8.3 TSA RECOMMENDATIONS

8.3.1 Highway Security-Sensitive Materials (HSSM) Security Action Items, Transportation

Security Administration, U.S. Department of Homeland Security: Arlington, VA, 2008.
Web site: https://www.tsa.gov/

8.4 EPA REGULATIONS

8.4.1 Code of Federal Regulations. Title 40. Part 150. Office of the Federal Register National
Archives and Records Administration. U.S. Government Printing Office: Washington,
DC, (revised annually).

8.5 OSHA REGULATIONS

8.5.1 Code of Federal Regulations. Title 29. Part 1910. Office of the Federal Register National
Archives and Records Administration. U.S. Government Printing Office: Washington,
DC, (revised annually).

8.6 CANADIAN REGULATIONS

8.6.1 Canadian Transportation of Dangerous Goods Act and Regulations, Transport Canada:
Ottawa, Ontario, 2009. Website: http://www.tc.gc.ca/tdg.

8.6.2 Canadian Environmental Protection Act, 1999 (CEPA 1999) and E2 Regulations;
Environment Canada: Gatineau, Quebec, 2013. Website:
http://www.ec.gc.ca/eeue/default.asp?lang=En&n=9605FFBD-1.
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 25

8.7 OTHER CHLORINE INSTITUTE PUBLICATIONS

The following publications provide useful information in addition to the publications

reference herein. The latest editions of CI publications may be obtained at
http://www.chlorineinstitute.org.

Pamphlet Title

1 Chlorine Basics; Ed. 8, Pamphlet 1; The Chlorine Institute:

Arlington, VA, 2014.

17 Packaging Plant Safety and Operational Guidelines; Ed. 5,

Pamphlet 17; The Chlorine Institute: Arlington, VA, 2017.

64 Emergency Response Plans for Chlor-Alkali, Sodium

Hypochlorite, and Hydrogen Chloride Facilities; Ed.7, Pamphlet
64; The Chlorine Institute: Arlington, VA, 2014.

For further assistance and information on items referenced, contact the following organizations:

Director, Office of the Federal Register American Trucking Association

National Archives and Records Administration 950 North Glebe Road, Suite 210
8601 Adelphi Road Arlington, VA 22203-4181
College Park, MD 20740-6001 703-838-1700
1-866-272-6272 https://www.trucking.org/
https://www.archives.gov/

Superintendent of Documents National Association of Chain

Government Printing Office Manufacturers.
Washington, DC 20402 28175 Haggerty Road
202-512-1800 (sales) Novi, MI 48377
https://www.gpo.gov/ 248-994-2222
https://www.nacm.info/

The Chlorine Institute Transport Canada

1300 Wilson Boulevard, Ste. 525 330 Sparks Street
Arlington, VA 22209 Ottawa, ON K1A 0N5
703-894-4140 866-996-9737 (toll free)
703-894-4130 (Fax) 613-990-2309 (direct)
www.chlorineinstitute.org 613-954-4731 (fax)
http://www.tc.gc.ca/eng/menu.htm
 26 PAMPHLET 76

APPENDIX A – PAMPHLET 76 CHECKLIST

This checklist is designed to emphasize major topics for someone who has already read
and understood the pamphlet. Taking recommendations from this list without
understanding related topics can lead to inappropriate conclusions.

Place a check mark () in the appropriate box below:

Yes No N/A
   1. Are all employees involved with the transportation of chlorine
containers properly trained as specified in 49 CFR or
Transport Canada’s Transport of Dangerous Goods Act &
Regulations? {3 and 4}

   2. If a common carrier is being used, are their drivers properly

trained and do they know how to activate the emergency
response plan? {7.3}

   3. Is the decking on the truck in suitable condition and of

acceptable materials of construction? {5.1.1}

   4. Are the correct placards displayed correctly on the four sides

of the truck? {3.1}

   5. Are the shipping papers correct including name, hazard,

quantity, RQ, etc.? {7.7}

   6. Is the loading and unloading equipment designed to handle {5.1.4,

the weight of the full containers or of full cylinders including 5.3.2 and
the weight of pallets? 5.4}

   7. Are containers properly secured to the unloading device {5.1.4,

before lifting them or moving them? 5.3.2, 5.4,
6.1.2}

   8. If chlorine containers are part of a mixed shipment with other

hazardous materials, are DOT’s separation table
requirements in 49 CFR being met? {7.2}

100 and 150 lb. (45.4 and 69.0 kg) Cylinders

   9. Are they upright and properly secured in at least two places? {5.1.2,
5.1.3,
5.1.4, 5.2,
5.3, 5.4}

   10. Are the chains or straps used to secure them in good {5.1.3,
condition? 5.1.4, and
5.3.2}
 GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 27

Ton Containers

   11. Is the bulkhead properly reinforced and designed to secure

tons? {6.1.2 }

   12. Are the individual containers chocked to prevent rolling? {6.1.2 }

   13. If chains are used, do they meet DOT or Transport Canada

requirements for the combined weight of the containers they
secure? {6.1.2 }

   14. Are nylon straps only used to secure an individual ton

container?
{6.3}
   15. Are you using a “C” clamp to connect the two end containers
at the chimes and is the clamp secured to the vehicle in case
it becomes loose? {6.1.2}

   16. If individual lockdown devices are used, are all tons properly {6.1.2 and
secured and is each device in the fully locked position? 6.3}

REMINDER:

Users of this checklist should document exceptions

to the recommendations contained in this pamphlet.
28 PAMPHLET 76

DRAWINGS
GUIDELINES FOR THE SAFE MOTOR VEHICULAR TRANSPORTATION
OF CHLORINE CYLINDERS AND TON CONTAINERS 29

DRAWING 122: TON CONTAINER LIFTING BEAM

 1300 Wilson Boulevard « Suite 525 « Arlington, VA 22209
Telephone: (703) 894-4140 « Fax: (703) 894-4130
Email: pubs@CL2.com « Website: www.chlorineinstitute.org
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