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Rh UNITED STATES OF AMERICA

WASHINGTON, D.C. ISSUED: April 25, 1973

FORWARDED TO:

Honorable John W. Ingram

Administrator

Federal Railroad Administration

Washington, D.C. 20590

SAFETY RECOMMENDATION R-73-13 & 14

The National Transportation Safety Board developed evidence at the public hearing in Chicago, Illinois, during the week of December 4-8, 1972, concerning the design of the highliner cars. The cars referred to were manufactured by the St. Louis Car Division of the General Steel Industries Inc.,and are owned by the Chicago South Suburban Mass Transit District. The Urban Mass Transportation Administration made a capital grant for a portion of the cost of these cars.

An analysis since the hearing indicates that the main vertical members (collision posts) in the highliner car involved in the collision of two commuter trains in Chicago, on October 30, 1972, did not meet the requirements of the Federal regulations. The conditions found indicate that the crash resistance of one collision post was reduced below the strength required by 49 CFR 230.457 and that this condition may exist in a number of other highliner cars. The Board believes, however, that this condition can be corrected.

It was disclosed at the hearing that there was incomplete fusion in about 75 percent of the weld attaching one collision post to the underframe. The collision post was secured to the underframe by a ½-inch-thick attachment plate, the bottom edge of which was beveled at a 45° angle for welding purposes. The depth of the bevel was only 5/16th of an inch instead of the full ½-inch thickness of the plate as originally designed and shown on the drawing. The 993C