Case Study: U.S. Based Railcar Manufacturer achieves AAR-compliant 60' flat car design with BNSF Logistics

AAR Compliant 60’ Flat Car Design with Rail Detection System

U.s. Based Railcar Manufacturer worked with **BNSF Logistics** to design a 60’ flat car for use as a rail train while meeting strict Association of American Railroads (AAR) structural and design requirements. The customer needed a solution to transport 1,600-foot-long, 140-pound rails with multiple shipping features, including an updated rail detection system for tunnel cars at both ends of the train.

**BNSF Logistics** engineered a compliant flatcar capable of carrying a gross rail load of 286,000 lbs., using finite element analysis and non-linear, large deflection stress calculations to verify performance. The design also included a center tie-down car, roller cars, and updated air and hydraulic systems, and it remains in successful operation today. The project improved fleet value and increased customer satisfaction.