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Technical and procedural LCAG-Guidelines for Shipper-built units

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Technical and procedural LCAG guidelines for Shipper-built units

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Modules for BUP500 and BUP1500

Page

General Requirements 3

Training requirements 5

Preface 7

Module 1 Lufthansa Fleet; Unit Load Devices (ULD) 8and Contours

Module 2 Serviceability of Unit Load Devices (ULD) 28Storage and Transportation of ULD and Nets

Module 3 Build-Up of Pallets and Container 43

Module 4 Additional requirements for special cargo 65- Dangerous Goods (DGR)- Insulation containers- Perishable good (PER- Live animals/day-old-chickens (AVI)

- Vulnerable goods (VUN)

Module 5 Unitization Program Declaration 72

Module 6 ULD Tag 75

Test yourself 81

Appendix I Answers to the Exercises and Test yourself 85

BUP1500 Supplement

Module 7 Loading of single pieces weighing up to 1.500kg 88

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General requirements

1. The units do not contain any of the following items:

a) Cargo subject to special security measures, e.g. valuable cargo (VAL),other vulnerable goods (VUN), works of art and other high-value cargoin danger of theft

b) Perishable goods (PER)

c) Live animals (AVI), except pallets with day-old-chickens only

d) Dangerous goods, except those items and articles as per Dangerous Goods-Regulations IATA-DGR 9.1.4.1 (ID 8000, UN 1845, UN 2807)

e) Oversized cargo exceeding the base dimensions of the ULD

f) Metal sheets and metal plates; plates made out of other materials with anindividual weight of more than 20 kg

g) Metal pipes and metal bars; Pipes and bars made out of other materials are onlyacceptable if loaded as required in the Guidelines

h) Unsecured cargo from unknown sources which would require security controlupon acceptance by Lufthansa Cargo

i) Lithium metal batteries subject to Section II of the IATA DGR packing instructions968 -970 ex / via / into the USA

2. Container Security Initiative (CSI) requirements: All ULD must be transported andstored in a secure environment.

3. Supply chain security is essential to ensure ULD are not manipulated or compro-mised to conceal or smuggle illicit narcotics, dangerous articles or improvised explo-sive devices.

4. Prior to and after using a ULD, a thorough inspection must be conducted to ensurethe ULD interior and exterior was not compromised (such as false bottom, sides,manipulation of curtain or door, etc).

5. The ULD will always be handled on slave pallets or roller beds during the entiretransportation and handling at the shippers/forwarders warehouse

6. The shipper/forwarder provides the complete and correct HAWB-data latestuntil LAT = Latest Acceptance time

7. LCAG is entitled to check the HAWB unless the consol manifest provides the re-quired information

8. Only transparent plastic foil may be used for pallets to allow visual inspection uponacceptance by LCAG

9. It is not permitted to use air or gas filled dunnage bags to secure the load inside acontainer

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10. LCAG is entitled to perform random checks at acceptance and audits at theshippers/forwarders warehouse. The Shipper/Forwarder agrees to accommodatesuch checks and audits after prior agreement

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Training Requirements

Staff members entrusted with ULD build-up must be qualified according to the weight limita-tions per individual piece.

weight limi tat ion required qual if icat ion

up to 500(BUP500)

Every employee must be familiarized with the contents of theTechnical and procedural LCAG-Guidelines for pre-built units( self-studying )

up to 1500(BUP1500)

Every employee must be familiarized with the contents of theTechnical and procedural LCAG-Guidelines for pre-built units( self-studying ) andit must guaranteed on the part of the forwarder/shipper thatenough BUP 1500 qualified staff ( training course ) are re-sponsible for supervision and controlling the built-up incl.Signing for the correct built-up of the units

up to 9500(BUP9500)

Every employee must be familiarized with the contents of theTechnical and procedural LCAG-Guidelines for pre-built units( self-studying )

and

it must guaranteed on the part of the forwarder/shipper thatenough BUP 9500 qualified staff ( training course ) are re-sponsible for supervision and controlling the built-up. incl.Signing for the correct built-up of the units

Required documents and additional information can be obtained via the local LufthansaCargo AG office.

The BUP qualifications are always applicable to the participant, not to the forwardingagency/shipper enterprise

BUP/SMU shipper/forwarder acts on behalf of respectively in agreement with Lufthansa

Cargo, which means acting as an operator's agent.

As the staff is involved in the acceptance of cargo and the build-up of BUP/SMU, they aresubject to the IATA-DGR training requirements for staff categories 6,7 and 8.

a) Category 6 is mandatory for the acceptance of the permitted dangerous goodsICE (used for cooling of non-dangerous goods) and ID8000.For MAG the category 7 is sufficient.

b) Category 7 staff is defined as " operator's and ground handling agent's staff ac-cepting cargo other than dangerous goods"

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c) Category 8 staff is defined as "operator's and ground handling agent's staff re-sponsible for the handling, storage and loading of cargo".

Normally the freight forwarder's staff is subject to the IATA-DGR training requirements forstaff categories 3, 4 or 5. This is applicable if the freight forwarder acts as shipper's agent.

As a BUP/SMU customer, the freight forwarder becomes an agent for the operator andtherefore the staff must be trained accordingly.

Currently there are no BUP refresher trainings

Concerning ICAO/IATA requirements the refresher trainings for DGR 6, 7 and 8 must alsotake place latest within 24 months.

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Introduction

Every day hundreds of Lufthansa aircraft take off and land. They carry thousands of pas-sengers, tons of mail and even more tons of cargo to almost all corners of the world.

OurCustomersrely on Lufthansa Cargo to transport their cargo and mail without undue

delay or damage.

OurPassengersrely on Lufthansa to transport them and their baggage in order that they

reach their destination safely.

OurCrewsrely on the correct and safe loading of the cargo in our aircraft.

All of them expect that whatever has been loaded inside the aircraft has been done so ac-cording to the regulations.

With this guideline, you will get to know the safety factors involved when building up ULD,as well as YOUR responsibil itytowards your/our customers, our passengers, crew and

aircraft.

These guidelines are based on the LCAG rules GOM (Ground Operations Manual) andCHM (Cargo Handling Manual)

At the end of each module you will find some exercises.After completing all modules and exercises you will find a Test Yourself covering all topicsof this guideline. The answers are given in Appendix I.

Well if you are ready, lets start.....

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Module 1 - The Lufthansa Fleet

On the following pages, you will get to know the Lufthansa fleet.

Furthermore you will find the corresponding unit load devices for each type of aircraft.

For the build-up of pallets, we have listed the maximum contour for the correspondingtype of aircraft. The maximum dimensions mustbe observed.

The gross weight listed at the corresponding unit load device must not be exceeded.

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A320 A321

The maximum loading height in the Lower deck is 116 cm (45.6 in) - including the

ULD base.

The following uni t load devices are loadable on board aircraft types A320 / A321:

Unit Load Device AKH / AKW PKC

Volume 3.5 m

MaximumGross Weight 1134 kg 1134 kg

Each side-extension m ay be loaded with a maximum of 350 kg(no heavy pieces)

Lower Deck Main Deck

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Maximum contour

If a PKC pallet is built-up the contour (H) must not exceed the maximum dimensions as shown below(dimensions including pallet-base)

H

1.16m

45,6

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A330 / A340

The maximum loading height in the Lower deck is 163 cm (64 in) - includ ing the ULDbase.

The following uni t load devices are loadable on board aircraft types A330 / A340:

Container

Unit Load Device LD3 AMP RAP

AKE, AVE, AVA

Volume 4.0 m3 10.0 m3

MaximumGross Weight 1588 kg 5103 kg 4626 kg

88 and 96 pallets

Unit Load Device 88 = 318 x 224 cm 96 = 318 x 244 cm with side-extension

PAG, PAJ PMC PAW PMW

Maximum 4626 kg 5103 kg 4626 kg 5103 kgGross Weight

Each side-extension m ay be loaded with a maximum of 600 kg.(no heavy pieces)

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Maximum contour

If a pallet is built-up the contour (F) must not exceed the maximum dimensions as shown below (dimensionsincluding pallet-base).

F

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A 380

In the Lower deck the maximum loading height is 163 cm. (64 in), including the ULDbase

The following load devices are loadable on the A 380

Container

Unit Load device LD3 AMPAKE, AVE, AVA

Volume 4.0 m3 10.0 m3

Maximum 1588 kg 5103 kgGross Weight

88 and 96 pallets

Unit Load device 88 = 318 x 224 cm 96 = 318 x 244 cm with side-extension



Each side-extension m ay be loaded with a maximum of 600 kg.(no heavy pi eces)

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Maximum contour


F

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B747

In the Lower deck the maximum loading height is 163 cm. (64 in) - including the ULDbase

The following load devices are loadable on board aircraft type B747:

Container

Load Device LD3 AMP AKE, AVE, AVA

Volume 4.0 m3 10.0 m3

MaximumGross Weight 1588 kg 4626 kg (5035 kg )

88 and 96 pallets





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Maximum contour

If a pallet is built-up the contour (U) must not exceed the maximum dimensions as shownbelow (dimensions including pallet-base).

U

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B747F

In the Main deck the maximum loading height is 300 cm (118 in), inc luding the ULDbase

The following load devices are loadable on board aircraft type B747F ( Main deck )

Container

Unit Load Device MD11F / 10 ft ContainerAMH / AMJ

Volume 15.0 m

Maximum 6803 kgGross weight

88 and 96 pallets

Unit load Device 88 = 318 x 224 cm 96 = 318 x 244 cm

PAG, PAJ PMC

MaximumGross Weight 6803 kg 6803 kg

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Maximum contour

If a pallet is built-up contour must not exceed the maximum dimensions as shown below(dimensions including pallet-base)

AD

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MD11F

In the Lower deck the maximum loading heigh is 163 cm. (64 in), including the ULD

base

The following load devices are loadable on board aircraft type MD11F

Container

Unit Load Device LD3 AMP

AKE, AVE, AVA

Volume 4.0 m3 10.0 cm3


88 and 96 pallets





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Maximum contour

If a pallet is built-up the contour (F) must not exceed the maximum dimensions as shownbelow (dimensions including pallet-base).

F

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MD11F

In the Main deck the maximum loading heigh is 254 cm, includ ing the ULD base

The following load devices are loadable on the MD 11F ( Main deck )

Container


Volume 15.0 m

Maximum 6803 kgGross Weight

88 and 96 pallets

Load device 88 = 318 x 224 cm 96 = 318 x 244 cm

PAG, PAJ PMC

Maximum 4109 kg 4109 kg (6803 kg * )Gross Weight

* not possible for all positions in the aircraft

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Maximum contour

If a pallet is built-up the contour (CII) must not exceed the maximum dimensions as shownbelow (dimensions including pallet-base).

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B 777F

In the Lower deck the maximum loading height is 163 cm. (64 in), including the ULDbase

The following load devices are loadable on the B 777F

Container

Unit Load device LD3 AMPAKE, AVE, AVA

Volume 4.0 m3 10.0 m3


88 and 96 pallets

Unit Load device 88 = 318 x 224 cm 96 = 318 x 244 cm with side-extension



Each side-extension m ay be loaded with a maximum of 600 kg.(no heavy pi eces)

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Maximum contour


F

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B 777F

In the Main deck the maximum loading height is 300 cm ( 118 in ), including ULD base

The following uni t load devices are loadable on B 777F ( Main deck )

Container


Volume 15.0 m

Maximum 6803kgGross weight

88 96 paletts

Unit load Device 88 = 318 x 224 cm 96 = 318 x 244 cm

PAG, PAJ PMC

Maximum

Gross Weight 6803 kg 6803 kg

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Maximum Contour

If a pallet is built-up the contour (J4) must not exceed the maximum dimensions as shownbelow (dimensions including pallet-base).

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Exercises to Module 1

1) What is the maximum loading heightin the lower deck of a B747 aircraft?

_____________ cm

2) What is the maximum weightof a AMP container loaded in the lower deck ofan Airbus A340 aircraft?

_____________ kg

3) What is the maximum contourpossible in the lower deck of an Airbus

A340 aircraft?

_____________ cm

4) What are the base dimensions of a PAJpallet?

_____________ cm

5) What is the maximum loadable length of a U-contour?

_____________ cm

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Module 2

2.1 Serviceability of Unit Load Devices (ULD)

2.2 Storage and transportation of ULD and nets

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2.1 Serviceability of Unit Load Devices

Before you start to load unit load devices with cargo, you must check their serviceability.Normally all ULD are checked prior to their release to the Agent/Customer. Nevertheless,we advise before you load take a look at the unit for damage.

Why must th is be done?

To explain this let us take any everyday example.

Many of us take a shopping bag along, in order to carry home all the things bought. If thebag is intact, it is no problem to take home all the things without loss or damage.However, what happens if the bag is already damaged before we use it ? Well the damagecan only increase. In the worst case, the bag may not be able to hold the things you havebought. This means, that the bag will tear further and perhaps damage your purchases oreven destroy them. Using common sense, everyone should check the bag before it is used.

Same as with shopping bags, the ULD are only built for a certain weight (see module 2).They can only be used if they are in good order. So you can see, this is another factor re-garding safety.

How can we check the serviceability?

We realize that this is not easy. But on the following pages we want to show you or to giveyou an idea, what to look for and where you must look! We know that under time pressure itis difficult to take time to check ULD, but now that you do have time, go through this chaptercarefully.

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All regulations are also valid for ULD from other airlines when transported on Lufthansa air-craft

Basic rules for all ULD

a) Type label or type markings must be affixed or engraved and readable.

b) It must be possible to restrain the ULD correctly in the aircraft with all necessaryrestraint elements. This means if you discover badly bent or bowed pallets theywill most probably not fit underneath the locking system in the aircraft. The resultbeing an offloaded pallet and angry customers.

c)

d) The door mechanism must work properly and must keep the load secure in thecontainer, regardless of the door construction (tarpaulin or door net or solid door)

X

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e) All ULD with damaged or missing pallet corners are to be consideredunserviceable

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Al l Metal containers (LD3, AKH, AKW, AMP, AMH, AMJ)

Unserviceable, if:

Rivets are missing.

In the remaining area:

a) one tear or crack of more than 25 cm perpanel or

b)more than 3 holes per panelc) if the space between any holes is lessthan 15 cm.

Frame profiles of walls:

a) one hole with more than 1 cm in diameter per profile;

b) one longitudinal crack with more than 4 cm length;

c) dents of more than 2,5 cm

over the whole length of profile;

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Al l Metal container(LD3, AKH, AKW, AMP, AMH, AMJ )

Unserviceable if:

a) the door frame is damaged

b) the base panel is damaged

Screws or rivets are missing orstiffeners

are damaged;

Screws or rivets are missing orgussets are

damaged.

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Addit ional for LD3 Containers

Unserviceable, if:

Door

a) hooks are missing;

b) door lock is damaged or missing.

Flexible door

a )steel cable is damaged or missing;

b) two tears of more than 10 cm length;

c) distance between 2 tears less than 20 cm.

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Serviceability of insulating containers (RAP, RKN)

An insulating container is not serviceable, if it has

a) any parts missing or

b) more than two missing or loose rivets in the container base next to each otheror

c) a hole or crack in the base (underneath or inside the container) or

d) a damaged door sealing or

e) a hole or crack in the side panels or roof panel.

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Metal container

Unserviceable, if:

Door nets

Cross stitching torn at fittings Straps damaged or torn

Missing or unserviceable fittings or hooks

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Pallets

Unserviceable, if: Panel

is damaged;

Edge-profile

a) more than 1 missing rivet or screw per side

b) damaged tie-down tracks nearer than 6 pairs of lips at the net attachment point;

c) has damages or cracks.

Pallet nets

a) more than 1 torn mesh per net;

b) missing or unserviceable net- fittings;

c) missing or damaged net lashingrope;

d) missing type plate (net marking);e) the net is older than 5 years;

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Tie-down material

Tie-down material is not serviceable, if

Tie-down ropesa) they are torn or cut orb) have torn fibres orc) they cannot be used any longer according to their specification

-

Tie-down rings -Tie-down fittings

a) they are damaged or distorted orb) parts of the ring are missing orc) the ring is open or

d) they cannot be used any longer according to their specification-

Tie-down strapsa) straps are torn or cut, orb) stitches are torn or missing, orc) tie-down rings are missing, damaged or distorted, or

d) the expiry date is exceeded(tie-down straps which do not show the expirydate must not be older than 5 years.)

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2.2 Storage and Transportation of ULD and Nets

To avoid damages of ULD, the following procedures are in effect and have to be strictlyadhered to.

Storage of empty containers:

preferably on roller racks or ball mats

1. on ground:

only allowed if two spacers are used underneath; spacers consist of eitherplastic foam material or wooden planks/skids

2. stacking:

a) on ground up to two is allowed (except AMJ / AMH containers) using spacersunderneath and in between

b) in a rack up to four allowed using spacersc) protection against strong winds is mandatoryd) container doors (tarpaulin or metal) must be closed to avoid damages of the

doors

3. Storage of empty pallets:

a) for alignment of pallets, a pallet rack (funnel) is mandatoryb) storage of up to 20 piled pallets in a shelf is the maximumc) to avoid excessive bending of wing pallets spacers must be used up to the

maximum of 5 pallets

4. Storage of nets:

a) serviceable nets are to be packed in a net bag (PN 115) and stored in dryrooms or

b) they must be stored in the middle of the piled pallets, providing one net for

each pallet (also in net bags)

Unserviceable nets are to be collected in an appropriate container and to be returned toLufthansa Cargo.

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Storage of loaded containers/pallets:

a) must only be stored on slave pallets or roller racks, ball mats or dolliesb) no storage on ground allowed (not even on spacers)!c) never use forklift for moving of loaded containers/pallets!

Transportation of empty containers:

a) preferably on dollies, slave pallets etc. but allowed by forkliftb) on trucks spacers must be used underneath if no roller beds or similar existc) on trucks piling up the maximum of two is allowed (except AMJ/AMH) using

spacers underneath and in between.

Transportation of empty pallets on ground:

a stack of 40 pallets maximum using slave pallets or dollies only.

Transportation of loaded containers/pallets:

a) on dollies allowed onlyb) never by forklift unless a slave pallet is used

c) on trucks/trailers slave pallets, roller beds or ball mats are mandatory;no exceptions!

Damages caused by disrespecting the above instructions will lead to invoicing of the re-sponsible party.

Return ing empty ULD and loading material (nets, straps, etc.) to Lufthansa Cargo

Pallets and containers must be returned cleaned. Straps have to be rolled up and nets mustbe packed into net sacks, one sack per net.

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Exercises to Module 2.1

1) Is this LD3 serviceable?

Yes

No

2) You are tasked to build up a pallet. When checking the serviceabilityyou realize a crack at the corner of the base plate.

Is this pallet sti ll serviceable?

Yes No

3) Please mark the box (s) where you think that according to the rules the pallet isunserviceable.

The net is four years old

A missing corner rope

One torn mesh

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Exercises to Module 2.2

1) What is the maximumamount of empty LD3 containers that are allowed to bestacked in a rack when spacers are also used.

3

2

4

2) Where are you allowed to store loaded ULD ?

on ball point mats

on the ground

on dollies

3) What do you have to observe when returning used empty containers to

Lufthansa Cargo?

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Module 3 - Build-Up of Pallets and Containers

3.1 Build-up of ULD

3.2 Floorload Capacity

3.3 Securing the load

It must not look like this !!!

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3.1 Bui ld-up of ULD (Pallets and Container)

What has to be observed when building up ULD?

Lufthansa Cargo has set up fundamental loading-rules which have to be observed!We will discuss every single item of these loading-rules and will give you some useful hintsand tips for your everyday work.

Fundamental loading-rules

Before loading an ULD, you have to check serviceability (see module 2).

For the load protection only LCAG-nets are to be used on LCAG-pallets

The ULD have to be handled carefully.

ULD may only be loaded on ULD dollies or on other devices equipped with

a roller-bed.

Do notload ULD directly on the ground - loading of ULD only on dollies or racks

Xslave pallet which supports the actual pallet

X

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Load heavy and unstable pieces as bottom layer and towards the centre of the pallet.

Use the bricklayer-principle when loading pieces of the same size.


The rim of the pallet has to be free of all kinds of cargo, to enable the attachment of the tie

down devices and to allow the pallet to be secured by the locking system in the aircraft.

Here some negative examples:

X

X X

Due to the planks loaded directly overthe pallet rim, the aircraft locks can-not be erected and secured thereforeit is not possible to restrain this ULDin the aircraft correctly.

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Light pieces should be placed on top of heavy pieces. This lessens the chance of damage.

This cargo was correctly built up

within the loading area of the pal-let. It will be no problem to restrainthe pallet in the aircraft.

X

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Pieces with a metal rim (for example: metal barrels) have to be placed on planks to prevent

the piece from moving and to increase the contact area (see floor load capacity module

3.2).

X

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MD11F Freighter

3.2 Floor load capacity

What is meant by maximum floor l oad capacity?

This expression is used to determine the structural limit of weight pressure per square me-

tre on the floor area of an aircraft.

Why do we need to know about maximum floor load capacity?

We must protect the floor area from being overloaded in order to avoid structural damage to

the aircraft. We do this by spreading the weight over a larger contact area. Its the same asan alpine skier putting on his skis to avoid falling through the snow. He has enlarged his

contact area meaning his weight has been distributed over a larger area.

Here an example of what must never happen!

To avoid exceeding the maximum floor load capacity we must not load more than 2000 kgper square metre (2000 kg/m) when we are using ULD.

wooden planks

X

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If we do not adhere to the above value we are endangering the safety of the aircraft!

How do we know whether the limits have been exceeded or not? ...

How do I calculate the maximum floor load capacity ?

Calculating the Contact Area

To know whether the maximum floor load capacity has been exceeded or not, we must firstof all calculate the actual contact area of our cargo. That means, the area of the box which

is actually touching the floor (in this case the chocks underneath). Do you remember yourschool days? : Length x Width = Area

The limit is 2000 kg per square meter so we must calculate our contact area in meters,meaning that the 10 cm becomes 0,10 m. So lets work out the contact area of one chock,0,1 m x 0,1 m = 0,01 m.

We have 4 chocks, so

0,01 m x 4 = 0,04 m = contact area of our piece.

Maximum weight allowed on th is contact area.

If we now multiply 0,04 m by our maximal allowed value of2000 kg/m we will get the fig-ure 80 meaning the maximum weight this piece may have is 80 kg.

If it weighs more than 80 kg or if we load other cargo on top, then the maximum floor loadcapacity will be exceeded.

10 cm

10 cmchock

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What must we do to avoid exceeding the maximum floor load capacity?

The answer is - Shoring.

We must enlarge the actual contact area. The best way to do this is to spread the weightby using wooden planks or supports. If we use planks then we mustuse a minimum oftwo.

Lufthansa Cargo has its own following standard planks:

- PN 050 (part number) 100cm x 15cm capacity 300kgs

- PN 051 150cm x 15cm capacity 450kgs

Other planks will do if they have a minimum of 2.8cm thickness and are made of good qual-ity timber. (The maximum capacity depends then on the length and width calculated in thesame way as before)

As stated earlier we must use at least 2 x PN 050 meaning we could load up to600 kg on these two planks.

XIn the case of such wooden

skids, the floor load capacity isnearly always exceeded.

Therefore:

Always use planks

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Drums and Barrels

With drums or barrels it is not easy to calculate the area, so as a golden rule: Always useplanks or supports. (Supports are wooden platforms designed for very heavy single

pieces which are used instead of multiple planks and may be ordered from LufthansaCargo)

Lufthansa Supports :PN 061 125cm x 75cm x 2,7cm capacity 1.875kgPN 062 200cm x 75cm x 2,7cm capacity 3.000kg

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3.3 Securing the load in general (Lashing)

When an aircraft takes off the cargo could move to the rear. The adjacent box must there-fore be lashed against the backward forces.

During landing or decent it could move forward. The box must therefore to be lashedagainst forward forces.

An upward force takes place when the aircraft is subject to turbulence and loses heightsuddenly. Also with a bumpy landing the same force applies. We therefore must secureagainst upward and the downward movement. For upward forces we alwayshave to useminimum tworopes or straps.

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To prevent any carefully positioned lashing material from slipping down the sides we mustuse an additional rope or strap which is called safety rope.

Now the so called standard lashingis completed.

Depending on the weight of your piece you may have to use additional ropes orstraps.

Loading princ iples regarding standard lashing:

a) Always lash the longest way round

b) Try to lash as close to the box as possible. By doing this you can make surethat the box will also not move to the side. Securing against the sidewaysforce is included when standard lashing procedure has been used .

(birds eye view).

----------- 50cm ---------------minimum 50 cm distance between tie down fittings pulling in the same direction

c) When a box has a height double its width then it must be lashed around allfour sides including the sideways force. This would be necessary withtall thin boxes.

X

X

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d) Keep a minimum distance of 50 cm (20) between two tie down fittings whenlashing in the same direction.

e) The safety rope must always point in flight direction (otherwise you havelashed the wrong side of your cargo).

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Lashing with straps or rope

Whatever is loaded in the aircraft must be secured in one way or another. The containersthat are loaded into the aircraft are secured by locks, but what about cargo loaded onto pal-lets?Normally a pallet net is used to secure all of the cargo on that particular pallet.If straps or ropes are used, it is essential that you use a sufficient amount corresponding tothe weight of the piece and that you lash the piece facing the right direction (flight direction).

On the next few pages we are going to explain the basic rules and regulations regarding the

lashing of cargo. These rules must be strictly adhered to!

First of all you need to know the flight direction.

In the lower deckof Lufthansa aircraft the pallet is usally loaded lateral to flight direction.( Exception A 380 ) This means the longest side of the pallet faces flight direction.

In the main deckthe pallet is usually loaded longitudinal to flight direction, meaning the

shorter side faces flight direction.

Flight direction

Flight direction

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Lashing Material

The Lufthansa Cargo lashing material available has different capacities, depending on con-struction and usage (against forward / backward / upward forces)

PN 040 Rope in connection wi th single stud fit ting PN 001

Forward / Backward 700kg

Upward 350kg

PN 034 strap

Forward / Backward 1000kg

Upward 500kg

PN 035 strap

Forward backward 2600kgUpward 1300kg

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Securing the pallet-load

Cover the pallets with plastic foil.

The cargo is preferably secured with a pallet-net.

Only LCAG-nets are to be used on LCAG-pallets.

On the edge of the pallet, next to the restraint device, net attachment point markings arelocated. These markings tell where the net has to be fixed to the pallet, five fittings on thelong side and four fittings on the shorter side of the pallet.

Al l net f it tings must be util ised, none are allowed to be miss ing or damaged.

Net attachment point

Load only in thisarea inside therim

Net lashing ropes areused to close the neton the corners.

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All four net lashing ropes have to be available, none are allowed to be missing or damaged.It is not allowed to increase the length, or repair the nets with ropes or straps!

Securing the pallet-load

In order to avoid accumulation of water and to secure the load against bad weather (rain,hail snow) cargo has to be protected by covering the pallet completely with plastic foil.

Nets have to be tightened so that no movement of load is possible.Howeverover-tighteningleads to damage of the cargo or bent pallets.

We also strongly suggest before loading apallet, cover the base with plastic foil, ensurethat the overlapping plastic gets tucked underthe plastic covering the load.

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Water can cause corrosion in the aircraft. If it is wet outside or you expect wet weather dur-ing ground handling and transport,

a) protect all pallets by an additionalplastic foil laid over the pallet net.b) Special rules apply to animals and perishables, please contact Lufthansa

Cargo AGc) make sure that the plastic foil is wrapped or tied to the pallet in a way that it

cannot be blown away.

Before the pallet is loaded in the aircraft, this additional plastic foil will be removed together

with any accumulated snow or water.

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Pipes and Bars

Metalpipes and metalbars may not be loaded in pre-built units.

Pipes and bars made out of other materials and beams or similar pieces (e.g. small andlong wooden boxes) must always be loaded opposite to the flight direction.

Loading these pieces in flight direction (a longitud inal loading) is not allowed due tosafety reason.

Because of their small cross section they might go through the pallet net meshing orthrough the forward or aft compartment walls.

In any case the ends of the pipes and bars protruding from the pallet must be secured witheither vertically placed planks or supports to protect the walls of the aircraft or by using atie-down spider (PN 039 - available from Lufthansa Cargo).Tie down straps (at least four depending the weight of the secured load) are fixed to orthrough the rings of the spider and then to the pallet base.

PN 039

Capacity: 6000 kg

Finally a net can be used to secure the complete load. (see picture)

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Securing the load inside a container

Attention has to be paid, that the pieces are stacked in a certain way, so that they will notfall out of the container when the doors are opened. To avoid having load pressing againstflexible container doors and causing bulges, pieces have to be skilfully stacked.

Internal lashing is required:

a) When single pieces can be damaged by them moving or falling

b) When single pieces with a heavy weight can cause damage to the containerc) When a container is loaded with less than two-thirds of the inner height

How do I lash internally?

Attach straps or ropes to the tie-down points inside the container. Pull them diagonallyacross on each side and use planks to secure the cargo.

wooden lanks ropes or straps

X

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Internal lashing is not required:

a) when the cargo mostly consists of light pieces with a small individual weight

b) when the container is completely full

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1) You are to build up a D-contour pallet for a B747 freighter. While attaching thenet to the pallet, you realize that the net is too short.

What action do you take?

Extend the net by the usage of double rope

Extend the net by the usage of straps

Use a bigger net, made for this contour

2) In which cases is internal container lashing not necessary?

a) _____________________________________________________

b) ______________________________________________________

c) ______________________________________________________

3) The piece shown below has the dimensions of 120cm x 80cm x 120cm(L x W x H) and weighs 180 kg. Six chocks with the dimensions of0.1 meter x 0.1 meter(10cm x 10cm) are attached underneath.

180kg

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Module 4 Loading of special cargo

4.1 Loading of Dangerous Goods (DGR)according IATA/DGR 9.1.4.1

a) ID 8000 consumer commoditiesb) UN 1845 dry ice (ICE) for cooling of non-dangerous goodsc) UN 2807 magnetized material (MAG)

4.2 Insulating containers

4.3 Other permitted special cargo

a) perishable goods (PER)b) live day old chickens(AVI/Chicks)c) valuable cargo (VAL) and vulnerable goods (VUN)

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4.1 Loading of Dangerous Goods (DGR) accordingIATA/DGR 9.1.4.1

Each Dangerous Goods shipment must be packed, marked and labelled according to theIATA-Dangerous goods Regulations.

The following requirements have to be observed when loading DGR:

Packages containing dangerous goods must be loaded in such a way that they cannot be

damaged. They have to be secured against movement and if required in an upright posi-tion.

Only packed dry ice may be used for cooling of cargo other than dangerous goods. This isalso applicable inside insulating containers.

To/from/over USA:

Effective 01October 2006the US authorities require a complete acceptance check (docu-ments and packages) for each dangerous goods shipment to/from/over the USA performedby the airline. This also applies to DGR permitted in pre-built units(ID 8000, UN 2807).

As there are various possibilities to comply with these requirements, a practicable and ap-propriate solution with the local LCAG office must be agreed upon.

For all units containing dangerous goods the ULD-Tag for DGR must be used (see module6).

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4.2 Addit ional requirements for the use of insulating container (RAP, RKN)

The RAPhas the base dimensions of a 224 x 318 cm (88 x 125 in) palette and a maximum

gross weight of 4 626 kg.The RKNhas the base dimensions of a LD3 Container 153 x 156 cm (60,4 x 61,5 in) and a

maximum gross weight of 1 588 kg.

When an insulating ULD (RAP/RKN) is used, please observe:

a) that batteries are installedb) check the required temperature is set

c) that the thermostat is switched ond) that the bottle for condensation water inside the container is emptye) that the fan is workingf) the fan is not blocked with other cargog) the internal maximum loading height is not exceeded (bottom edge of the fan)

If dry ice (ICE) is loaded in the dry ice bunker and/or inside the insulating container:

a) Always use the DGR-ULD Tag (see module 6)b) in addition to other required information under Remarks for special Loads

the following entry must be inserted:

9/ICE/ACT plus the total net quantity of d ry ice

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4.3 Build-up of AVI/Chicks, PER and VUN

The following commodities are not allowed to be built up without special permission fromLufthansa Cargo:

Day old chickens (AVI)

a) Boxes must never have direct contact with thepallet surface.

b) Put at least one layer of insulating material(e.g. planks min 2.8 cm thick) between theboxes and the pallet surface.

c) Put the chicken boxes on the planks laid outparallel to the longer pallet side, if possible.

d) For air circulation leave at least 15cm (6) ofspace parallel to the longer pallet side.

e) Tie down one of the middle rows of spacers to

stabilize the stacks on the pallet.

f) The maximum height for stacked boxesin thelower deck is 140cm (55); in the main deckeither10 layers of carton boxes or12 layers of plastic boxes.

g) Do not cover chicken boxes with plastic orsimilar material.

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Valuable cargo (VAL) and/or vulnerable goods (VUN)

a) You are only allowed to deliver VAL BUP in complete AVA container. Additionalseparate lose packages (overflow) are not permitted

b) You are only allowed to deliver VUN BUP in complete ULD.Additional separateloose packages (overflow) are not permitted.

c) Load vulnerable goods preferably into containers.d) Protect the vulnerable goods with two layers of plastic foil if loaded on pallets

(see also page 39 wet weather protection).

Perishable goods (PER)

Because of the huge number of perishable goods transported we only offer detailed infor-mation about the most common ones (PEF/PEP). In case you need further information tocorrectly load other perishable goods, please contact the local Lufthansa Cargo office to getthe necessary handling information.

In the table shown below you will find different perishable goods and their codes.

EAT Food for human or animal consumption (which is not PEP, PEMPES)

PEM Fresh meat and poultry and meat products (e.g. sausages)PPH Pharmaceuticals to be transported at a temperature between 10

and 300

CelciusPPL Pharmaceuticals to be transported at a temperature between

2 - 80 CelciusPER Other sensitive cargo (i.e. medicines, serum, blood plasma)PEF Fresh flowers and plantsPEP Fruit and vegetablesPES Fresh fish and seafood

All of them need to be labelled with the IATA label shown below:

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Furthermore:a) perishable goods must be properly packed,b) must be loaded in a way that the weight of the upper layers does not damage the

lower layers,c) the pallet is built in such a way that the contour remains intact.

Now some special handling rules forPEF(flowers and plants) and PEP(fruits and vegeta-

bles)a) Do not load flowers next to fruit or vegetables.

b) Make sure that there is space for sufficient air circulation between the packages(important for fresh fruit and vegetables with high moisture, e.g. grapes, berriesand lettuce).

c) If pallets with flowers, plants, fruit and vegetables are covered with plastic foil forweather protection, make sure that the foil does not cover more than 50 cm (20)from the upper rim of the contour to ensure sufficient air circulation.

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1. You want to load a shipment of Live Chickens on a 96 pallet for an Airbus A340 air-craft.

Each carton has the dimensions 60 x 40 x 23cm (L x W x H)

What is the maximum number of cartons that can be stacked high?

_________________________________________

2. You have received permission from Lufthansa Cargo to load tins of dog food as apre-built unit.What would be the special handling code for this type of commodity?

_________________________________________

3. You have loaded Dry Ice in the bunker of a RKN. Which remark has to be written onthe ULD Tag?

_________________________________________

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Module 5 Unitization Program Declaration

The next page shows as ample of the declaration - valid at the time of publishing.

The current declaration is to be received from your local Lufthansa Cargo Salesdepartment.

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Unit ization Program Declaration for Pre-built Units (BUP/SMU)

Valid for the period 01.01.2013 31.12.2015

Shipper/Forwarder:

Shipper/Forwarder and Lufthansa Cargo AG (hereafter called LCAG) hereby acknowledge that the pre-builtunits (hereafter called ULD) delivered under a Unitization program have to conform to the Technical and pro-cedural LCAG-Guidelines for pre-built units (hereafter called Guidelines) as well as the requirements of thisdeclaration to be acceptable for transportation on Lufthansa Cargo.

The Shipper/Forwarding Agent confirms that he has received and acknowledged the Guidelines. They alsocontain the LCAG training requirements. He agrees to and shall instruct staff members entrusted with build-upof units about LCAG rules for build-up, transportation and storage of ULD on the basis of the Guidelines andthis declaration. Proof about such instructions must be internally documented and filed. LCAG reserves theright to evaluate the content of the training used by the Shipper/Forwarding agent.

Furthermore he confirms that he observes the requirements of the Guidelines and of this declaration and thatthe pre-built units handed over to Lufthansa Cargo were build-up by qualified staff. By signing the ULD tag,the Shipper/Forwarding Agent confirms the correct build-up of each ULD and the observance of the require-ments of the Guidelines and this declaration for the respective ULD.

In case rented ULDs are not returned within 7 full days from the handover from Jettainer or any LCAG station,the ULD Demurrage Fee accrues with the commencement of the 8

thday, in accordance with the TACT Rules

(TACT abstract 8.3; Lufthansa 8.4). In order to avoid additional costs, the current amount of the rental dayscan be viewed on the automated ULD customer report under http://demurrage.jettainer.com/.

The Shipper/Forwarding Agent herewith assures that he has notified his customers of the stated exclusionsnamed under figure 1) for pre-built units through a proven system and that the cargo is properly booked, de-clared, documented and labelled and that the units do not contain any of the excluded special commoditiesnamed under figure 1).

To ensure the required flight safety and security the Shipper/Forwarder declares that in addition to the re-quirements of the Guideline the following articles are respected especially:

1) The units shall not contain any of the following items:

Cargo subject to special security measures, e.g. valuable cargo (VAL), other vulnerablegoods (VUN), works of art and other high-value cargo in danger of theft

Perishable goods (PER)

Live Animals (AVI), except pallets with day-old-chickens only

Dangerous goods, except those items and articles as per Dangerous Goods RegulationsIATA-DGR 9.1.4.1 (ID 8000, UN 1845, UN 2807)

Oversized cargo exceeding the base dimension of the ULD. For lower deck units the sideextensions (PKC, PLW, PAW, PMW) are included in the base dimensions of the ULD

Metal sheets and metal plates; plates made out of other materials with individual weightof more than 20 kg

Metal pipes and metal bars; Pipes and bars made out of other materials (except if loadedas required in the Guidelines)
http://demurrage.jettainer.com/http://demurrage.jettainer.com/

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Unsecured cargo from unknown sources which would require security control upon ac-

ceptance by Lufthansa Cargo

Lithium metal batteries subject to Section II of the IATA DGR packing instructions 968-970 ex / via / into the USA

2) Only transparent plastic foil shall be used for pallets to allow visual inspection upon acceptance byLCAG.

3) It is not permitted to use air or gas filled dunnage bags to secure the load inside a ULD.

4) LCAG is entitled to perform random checks at acceptance and audits at the shippers/agents ware-house at times and dates to be agreed upon. The Shipper/Forwarder agrees to accommodate suchchecks and audits.

5) The Shipper/Forwarder is authorized to load single pieces (HEA) within the ULD contour up to

6) The Shipper/Forwarder has obtained the special permission to delivervaluable (VAL) and/or vulnerable (VUN) goods as Safe/td2-BUP. Builtup is according to the specific requirements in the Built-Up Guidelinesfor BUP Units. Overflow for these kinds of goods is not allowed, the

number of pieces in the in the AWB shall show the actual number of units

7) The shipper/Forwarder has obtained the special permission to deliver unitscontaining solely perishable goods (PER, Cool/td)

In addition to the above mentioned rules and regulations the Shipper/Forwarder also declares, that the indi-vidual shipments loaded on pre-built units are Ready for Carriage according to the respective LCAG/TACTpublications and shipments correspond with documents and booked values especially referring to number ofpieces, weight and volume.

The Shipper/Forwarding Agent assumes liability for all damages or loss or any other irregularity to cargo aris-ing out of or connected (i) with the build-up of the ULD, (ii) the lack of Ready for Carriage status, and or (iii)with the fact, that the shipments do not correspond with documents and booked values. The Ship-per/Forwarding Agent shall indemnify and hold harmless Lufthansa Cargo AG for therewith connected claims

made by third parties.

Due to legal or regulatory provisions it may be mandatory

that the contens of each package within the ULD must be subjected to special securitymeasures. LCAG is not liable for any resulting delays in the forwarding of the shipments or forobserved discrepancies between the number of pieces loaded in the ULD ( SLAC shipper sload and count ) according to the AWB and the actual number of pieces loaded in the ULD.LCAG is only liable for direct damages culpably caused in relation to the special securitymeasures.

a) up to 500 kg

b) up to 1500 kg

c) up to 9500 kg

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to insert the number of pieces loaded into an ULD per shippers load and count (SLAC) in theAWB not only under Nature and Quantity of Goods but as well under number of Pieces.In such case this does in no way constitute any confirmation on part of LCAG to actually havereceived the SLAC number of pieces as contents of the delivered ULD. In this regard and tothat degree the shipper/forwarder does exempt LCAG from all claims own ones and thoseby third parties.

The Shipper/Forwarding Agent is entitled to deliver pre-built units at the following station/s:

LCAG is entitled to include new stations or exclude current stations as its sole discretion without giving reasonand upon prior notice (letter, fax, email) to Shipper/Forwarding Agent

This declaration is valid for the above mentioned three calendar years. LCAG reserves the right to revoke theauthorization to deliver ULD under the Unitization program with immediate effect at any time.

This declaration is exclusively governed by the laws of Germany. In case of disputes the courts of Frankfurtam Main, Germany shall have exclusive jurisdiction

Place/Date:

Shipper/Forwarder Lufthansa Cargo AG

Signature Printed Name/Signature

Regional Manager

Printed name

Title Printed Name/Signature

Regional Director

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Module 6 - ULD Tags

6.1 Use of the dif ferent ULD tags

6.2 Completion and affixing of ULD tags

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6.1 Use of the different ULD tags

For the identification of the various pre-built units different ULD tags are used.

Description Form Page (Markings)

ULD tag, standard 093000 front page

ULD tag, through unit 093000 back page (red circle)ULD tag dangerous gods,standard

3188021 front page: red and white diagonalstripes;back page: list of dangerous goods

ULD tag dangerous gods,through unit

566300 front page: red circle, red and whitediagonal stripes;back page: list of dangerous goods

ULD tag, td.Flash, standard 3063600 front page (td.Flash)

ULD tag, td.Flash, through

unit

3063600 back page (td.Flash, red circle)

ULD tag, td.Flash, danger-ous gods

3127900 front page: red and white diagonalstripes;back page : list of dangerous goods

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6.2 Completion and affixing of ULD tags

The information that is entered on the Tag is usually provided by the office staff.Every ULD must have a ULD Tag attached showing the ULD code, destination (3 lettercode) and the flight number/date.

The tag shown below is the standard tag.

You have to complete the following fields:

2

1

3

4

5 6

7

8

9

1

2

3

4

5

6

7

8

9

MIA

AKE 12345 LH

X

FRA LH 462/18

C

BUP 500PER

ID-Code ( ULD Code )

Destination

mark BUP box with an X

Signature of agent ( to confirm the correct built-up according to the LCAG guidelines and re-quirements )

Loaded at

Flight number and date

Contens (Cstands for cargo )

Enter either BUP500, BUP1500 or BUP9500 toendorse the maximum weight o f any singlepiece within the load and also the built upagents qualification( according to Unitized Program Declaration

Remarks fo r special loads ( 3 letter code forspecial load

In case side extentions are used you have towrite the code PWG( pallet with wings used )in the remarks box.

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According to the procedure for pre-built units, the shipper/forwarder is not allowed to enter aweight on the tag.The ULD weight is entered on the tag after acceptance by Lufthansa Cargo incl. signatureWeight correctly established and ULD correctly built-up (after visual inspection of properoutside condition)

With the special products ( e.g. Cool ) additional info can be necessary pls see IATATACT ( The Tarif Cargo Tariff Manual ) 8.3.8 Special rules and regulations

As an alternative to a already filled out ULD-tag by the forwarder/shipper it is also sufficient,if with the cargo acceptance a document ( e.g. Excel/Word Sheet ) of the forwarder isavailable, in which the a.m. ULD-tag info ( Pt 1- 9 ) is shown.- incl possible additional infoconcerning IATA TACT 8.3.8 Special rules and regulationsWith this information the ULD-tag can be issued by our own staff/our handlingsagent.The document of the forwarder/shipper has to be filed within a stationfile.

This alternative procedure must be agreed in advance with the local management

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If permitted dangerous goods are loaded in the unit, the applicable DGR-ULD tag must beused.

Shown is the ULD tag, dangerous goods standard (Form 3188021).

Affix ing:

a) For containers use the pouch.b) For pallets affix the tag to the net at eye level.

ID-Code:

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Exercises to module 6

1) You have already built up the pallet shown below (PMW 05326LH)for a flight (LH 450) from Frankfurt (FRA) to Los Angeles (LAX).

The pallet was built up in agreement with the Unitized Program Declaration (up to500kg). No dangerous goods are loaded.

Please choose the correct tag and fill in the appropriate fields.

ID-Code:ID-Code:

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Test yourself

1. Is the container shown below serviceable? If not please explain why.

_____________________________________________

2. Is this an acceptable way to handle a loaded ULD? If not please explain why.

_____________________________________________

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3. Please have a look at the picture below. The actual weight of this piece of cargo is320 kg.

The dimensions of the chocks (there are 9 of them!) is 0.1 m x 0.03 m(length x width).

Is supporting material necessary and if so how many PN 051 are neededto support that piece of cargo?

_________________________________

4. Which contours are loadable in the Lower Deck of a B747?(Only one answer is correct)

a) P, E, U, A, D

b) U, E, P, F

c) P, A, E, U, R

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5. Are you allowed to load a piece of cargo in a pre-built unit showing thefollowing label?

Please give a reason

6. Are you allowed to load a piece of cargo in a unit showing the following label?

Please give a reason

7. You are loading a 96 ULD for an Airbus A340 aircraft. You have apiece of cargo with the following dimensions:

302 / 252 / 60 cm (L x W x H )

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Are you allowed to load this piece on a pre-built unit? Please state the reason.

8. What is the maximumcapacity of a rope (PN040) used with asingle stud fitting (PN001) when used to restrain against upward forces?

700kg 1.000kg 350kg

9. You have the qualification for loading pieces up to a maximum weight of500kg. What would be the entry on the ULD-Tag in the remarks column?

10. You intend to load a unit with a shipment of 140 identical pieces eachweighing 31kgs. You use a 96 ULD (tare weight 115kgs) and it is planned foran Airbus A 340.

Which additional weight could you still load on the ULD?

a) 648 kg

b) No more

c) 171 kg

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Appendix 1

i) Answers to the Module Exercises

ii) Answers to the Test Yourself Exercise

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Answers to Modules

Module 1

1) 163 cm 2) 5 103 kgs 3) F 4) 318 x 224 cm 5) 472cm

Module 2.1

1) No 2) No 3) missing corner rope

Module 2.2

1) 4 2) on ball point mats and on dollies

3) ULD must be returned cleaned

Module 3

1) use a bigger net

2) full containers and with packages of low single weights

3) 120 kg

Module 4

1) 5 cartons (due to the planks underneath 6 cartons are not possible)

2) EAT 3) 9/ICE/ACT total net quantity of dry ice

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Module 5

1) PMW 05326LHLAXcross in BUP boxYour signature in the field Agents signatureLoaded at FRAFlight LH450/dateContents: CRemarks for special loads: BUP500

ii) Answers to the Test Yourself

1) No. The hole is too big.

2) Yes as long as a slave pallet is used.

3) Yes! Minmum 2 PN051 (3 is also OK!) The max. weight allowed is only 54kg ( 0.1 x 0.03 x 9 x 2000 = 54kg)

4) b)

5) No! This type of dangerous good (DGR) is not allowed on a pre-built unit

6) No! It is a dangerous good only permitted on freighter aircraft.

7) No overlaps allowed (252cm width)

8) 350kg

9) BUP500

10) 648 kg (dont forget to subtract the tare weight of 115 kg)

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Supplement for BUP1500 Agents

Module 7 Heavy pieces with an individual weight up to 1.500kg

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Heavy pieces with a single weight up to 1.500kg

Floorload capacity

For some types of awkward heavy pieces it might not be possible/sufficient to distribute theweight by using normal planks of wood (PN 050 or 051). In such cases supporting platformsare available.

There are two different sizes:

Type Dimensions max. capacity(part number)

PN 061 125 cm x 75 cm x 2,7 cm 1 875kg

PN 062 200 cm x 75 cm x 2,7 cm 3 000kg

TN 061TN 062

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Loading principles

Light pieces are to be loaded on top of heavy pieces to lessen the chance of damage

Heavy and sturdy pieces are to be loaded as a first or bottom layer. They should bestowed towards the centre of the pallet

Two negativeexamples to show what can happen if the piece or load is not evenly distrib-

uted.

1.500 kg 1.500 kg

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Editorial

If more and detailed information is needed, Lufthansa Cargo AG offers special ULD build-up courses for shippers and forwarding agents.

Details can be obtained from:

Lufthansa Cargo AGLufthansa Training & Conference Center Seeheim

Lufthansaring 1D-64342 Seeheim-Jugenheim+49 (0)69 696 71079

Responsible for the contents: Lufthansa Cargo AG, QSH F/PE, FRA F/OH.

Copyright:

No part of this manual may be reproduced, reworked, transformed or conveyed without previous agreement inany way, is it electronic or mechanical , including photocopy, redition or other information storage.The previous agreement must be caught up by

L fth C AG Gl b l H dli M t FRA F/OH

BUP Guideline 2013 09

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