Types of railcars

Each year, billions of tons of freight are transported by rail. To support this, railroad companies choose from a wide range of railcar types, each designed for specific cargo types and logistical needs. In this article, we discuss the most common types of freight railcars.

But let’s start with a little terminology. In this industry, various terms are used for railcars. Common alternatives include freight train cars, railroad cars, and railroad freight cars.

This overview is particularly relevant for readers who are considering leasing or purchasing railcars, or who are looking for more information about the applications and specifications of different railcar types.

Railcar types and their applications in different industries

Coil cars are purpose-built railcars designed for transporting coiled steel, aluminum, or copper used in the automotive, construction, and manufacturing industries. They are generally 50 to 60 feet long and equipped with trough-like wells that cradle the coils securely. Many coil cars feature removable hoods to protect sensitive metals from moisture, debris, and temperature fluctuations during transit. A single coil car can carry multiple coils, with total load capacities typically up to 100 tons.

The main advantage of coil cars is their ability to safely move heavy and high-value metals in bulk, ensuring protection and stability. However, their specialization means they have limited flexibility for other cargo types. Proper loading practices are important, as coils must be evenly distributed and secured to avoid shifting that could damage the cargo or compromise rail safety.

From a regulatory perspective, coil cars must meet Association of American Railroads (AAR) and Federal Railroad Administration (FRA) standards for load securement, structural strength, and inspection frequency. Special attention is given to hood integrity, tie-down systems, and handling procedures, as non-compliance can lead to severe safety hazards and costly product losses.

Flatcars are open-deck railcars without sides or a roof, making them one of the most versatile equipment types in rail freight. Standard flatcars range from 60 to 89 feet in length and can carry up to 100 tons of cargo. Their open design allows for the transportation of oversized or irregularly shaped loads that do not fit into enclosed cars, such as machinery, wind turbine blades, steel beams, military equipment, and intermodal containers.

The main advantage of flatcars lies in their flexibility: they can handle freight of nearly any dimension, provided it is properly secured. However, the absence of weather protection exposes cargo to rain, snow, and debris, which can be a disadvantage for sensitive goods. Specialized versions include bulkhead flatcars, equipped with end-walls to prevent loads like lumber or pipes from shifting during transit.

From a safety and regulatory standpoint, flatcars must comply with Association of American Railroads (AAR) guidelines regarding weight distribution, tie-down methods, and inspection intervals. Securement is critical, as improperly fastened loads can create serious hazards. When used correctly, flatcars provide a reliable solution for industries that depend on moving large, heavy, or unconventional freight.

Centerbeam railcars are flatcars with a central longitudinal beam that divides the car into two equal loading areas. They are typically 73 to 73.5 feet long and designed to carry bundled building materials such as lumber, plywood, wallboard, and other construction products. Each side of the centerbeam is loaded symmetrically to ensure balance and structural stability, with a maximum load capacity of around 200,000 pounds (100 tons).

Centerbeams are highly efficient for industries in the construction supply chain, as they allow for quick loading and unloading with forklifts directly from either side of the car. Their open design, however, makes them unsuitable for cargo that requires weather protection, and strict loading rules must be followed to prevent tipping or shifting.

Safety and regulatory compliance are critical: the Association of American Railroads (AAR) mandates that centerbeams be loaded evenly across both sides, with securement using appropriate tie-downs or straps. Failure to follow these standards can cause instability during transit, posing risks to cargo, crew, and equipment. When used correctly, centerbeams provide a cost-effective and reliable solution for transporting high-volume building materials.

Gondolas are open-topped railcars with fixed sides, designed for hauling heavy bulk commodities that do not require protection from the weather. They are typically 52 to 65 feet long, with load capacities up to 110 tons. Common cargo includes coal, scrap metal, aggregates, steel products, and construction debris. Their rugged construction makes gondolas a workhorse for industries such as mining, steel, and construction.

The main advantage of gondolas is their ability to carry dense, heavy, or irregular materials that are difficult to load into other car types. Unloading is usually done by rotary dumpers or through manual equipment such as cranes and grabs, which can be less efficient than gravity discharge systems used in hoppers. Additionally, exposure to rain or snow can affect some cargoes, leading to higher handling or cleanup costs.

From a regulatory and safety perspective, gondolas must comply with Association of American Railroads (AAR) standards on structural integrity, loading limits, and inspection schedules. Loads must be properly distributed and secured to prevent spillage or imbalance during transit. Despite their simple design, gondolas remain one of the most dependable options for transporting raw and recyclable materials in bulk.

Covered hoppers are enclosed railcars with sloped floors and bottom discharge gates, specifically designed for the transport of dry bulk commodities that must be protected from moisture. Standard covered hoppers range from 50 to 60 feet in length, with load capacities of up to 100 tons. Depending on the configuration, they may feature two to four compartments, allowing different cargoes to be carried in a single trip.

Typical industries that depend on covered hoppers include agriculture, food processing, and chemicals. Common commodities are grain, flour, sugar, fertilizer, cement, and plastic pellets. The main advantage of covered hoppers is efficient loading from the top and rapid unloading through gravity discharge at the bottom. However, cleaning requirements can be strict, as residues may contaminate sensitive cargo such as food products.

From a safety and compliance perspective, covered hoppers must meet Association of American Railroads (AAR) and Federal Railroad Administration (FRA) standards regarding hatch integrity, discharge mechanisms, and structural performance. Proper sealing is critical to prevent product loss, contamination, or exposure to the elements. When maintained and operated correctly, covered hoppers offer a reliable and cost-effective solution for the bulk transport of moisture-sensitive goods.

Tank cars are cylindrical railcars designed for the transportation of liquids and gases, ranging from food-grade products like corn syrup or vegetable oils to hazardous chemicals, fuels, and liquefied gases. They vary in size, with typical lengths between 23,000 and 33,000 gallons, and can carry loads of up to 100 tons. Depending on the cargo, tank cars may be pressurized or non-pressurized and often include protective features such as thermal insulation, head shields, and reinforced valves.

Industries such as energy, chemical manufacturing, agriculture, and food processing rely heavily on tank cars for bulk transport. The major advantage of tank cars is their ability to move large volumes of liquid safely and efficiently. A limitation is their high degree of specialization. Once designated for a specific commodity, cars must be thoroughly cleaned and requalified before switching to a different cargo type.

Tank cars are subject to strict safety and regulatory oversight. In North America, the Association of American Railroads (AAR) and the Federal Railroad Administration (FRA) mandate standards for design, maintenance, and inspection. Hazardous materials are regulated under PHMSA’s Hazardous Materials Regulations (HMR), requiring specific placards, pressure relief devices, and routing protocols. These measures minimize environmental and safety risks while ensuring compliance in the transport of sensitive or dangerous cargo.

Intermodal railcars, also known as well cars or double-stack cars, are designed to transport standardized shipping containers, suitable for intermodal transport. Their recessed “well” structure allows containers to be stacked two high, maximizing capacity and efficiency. Typical lengths range from 40 to 80 feet, accommodating one or multiple containers, with a maximum gross weight of around 100 tons per unit.

These cars are a backbone of global supply chains, serving industries such as retail, consumer goods, automotive, and electronics. Their key advantage lies in seamless transfer: containers can move directly between ships, trucks, and trains without reloading the cargo itself. This reduces handling time, lowers labor costs, and minimizes the risk of product damage. The main limitation is infrastructure dependency. Double-stack operations require sufficient tunnel and bridge clearances, which are not available on all routes.

From a safety and regulatory perspective, intermodal railcars must comply with Association of American Railroads (AAR) and Federal Railroad Administration (FRA) standards concerning load securement, structural design, and stacking configurations. Containers must be locked with interbox connectors (IBCs) to prevent shifting during transit. By ensuring compliance and proper handling, intermodal railcars provide an efficient, cost-effective, and environmentally friendly solution for long-distance freight transport.

Niels Pas

CEO Hoefon Security Seals

Niels Pas has been Hoefon Security Seals’ CEO since 2017. He has extensive international experience and speaks 4 languages professionally.

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