HLCL Container Inspection Manual
-
Upload
alexis-antonio-francois-reyes -
Category
Documents
-
view
592 -
download
35
Transcript of HLCL Container Inspection Manual
1
Hapag-Lloyd Container LinieContainer Inspection Manual
Version 1.0April 2006
2
Scope
This Manual is based on the “Hapag-Lloyd Repair and Inspection Guidelines”as well as additional Instructions generated from know-how and experience during the past decades of Container operation.The purpose of this Manual is to assist Hapag-Lloyd M&R Inspectors to evaluate which damages to a Container under Hapag-Lloyd’s custody require repair and which damages are to be considered “acceptable” and as such does NOT require repair. Furthermore the manual will recommend repair methods for individual damages indicated. However, it is not possible to describe every kind of damage/repair in this guideline. As such the local Inspector is invoked to be able to make a decision based on COMMON SENSE. In case of doubt, please contact Hapag-Lloyd Container Engineering Department (2812) for assistance.
Container Inspection Manual
3
Introduction
GENERALItems not specifically detailed in this Manual are covered by this general introduction only if they require repair;The tolerances / permitted damages listed are not the minimum necessary to meet basic requirements but are selected to ensure the container is serviceable while minimizing the need for repair and thereby preserving asset life;The repair method selected should be the most economical and suit the particular repair location
Container Inspection Manual
4
Introduction
ACCEPTABLE DAMAGEThis is defined as damage that is not to be repaired and includes:
All flange damages, unless the structural integrity of the container is compromised;Deformation of structural members up to ISO +10mm on the side face and ISO +5mm on the end face;Previous repairs should not be reworked unless the structural integrity of the container is compromised or it is unsuitable for cargo.
Container Inspection Manual
5
Introduction
NON-ACCEPTABLE DAMAGEThis is defined as damage that must be repaired because:
The International Convention for Safe Containers, 1972, as amended (CSC) is violated and container safety is affected:The Customs Convention is violated;There is a reduction in the internal height dimension by more than 70mm and/or the internal width/length dimension by more than 50mm;The container is unsuitable for cargo;Cracks in welds are present unless otherwise stated;Corrosion which causes loss of structural integrity
Container Inspection Manual
6
Introduction
WEAR & TEARThis is defined as unavoidable change or deterioration of the condition of the container brought about by routine operational use and includes:
Corrosion;General paint deterioration;Deterioration of door gaskets and fittings;Deterioration of door fixings arising from deterioration of doors;Floor de-lamination resulting from routine cargo loading and unloading cycles
Container Inspection Manual
7
Introduction
MANUFACTURING DEFECTS
Manufacturing defects or suspected manufacturing defects are to be reported to Hapag Lloyd Container Engineering Department (2812).
Container Inspection Manual
8
Bottom side rails
Container Inspection Manual
Holed, cut, torn, broken, cracked, deformation exceeding 50mm.
Weld or straighten, or straighten and weld, or insert, or section, or renew.
Flange dented, cracked, or cut, NOT going into radius or being in the weld joint to corner post or corner casting.
No action required.
Flange, cracked, or cut, or broken in the weld joint to corner casting, or going into web radius.
Straighten and weld, or insert.
Bottom side rail dented less than 50 mm, No action required!
Bottom side rail improper repaired (weld seam broken).Rework or insert required!
9
Bottom side rails
Container Inspection Manual
Example of Hapag-Lloyd Bottom side rail reinforcement with notched lower bottom side rail and cross member flanges
10
Front and Rear sill
Container Inspection Manual
Holed, cut, torn, broken, cracked, deformation exceeding 50mm.
Weld or straighten, or straighten and weld, or insert, or section, or renew.
Flange dented, cracked, or cut, NOT going into radius or being in the weld joint to corner post or corner casting.
No action required.
Flange, cracked, or cut, or broken in the weld joint to corner casting, or going into web radius.
Straighten and weld, or insert.
Front sill dented if less than 50 mm.No action required!
Rear sill dented (and cut) more than 50 mm.Repair by inserting recommended!
11
Cross member
Container Inspection Manual
Web holed, cut, torn, broken, cracked Weld or straighten, or straighten and weld, or insert, or section, or renew.
Web deformed in excess of 75mm Straighten, or renew.
Web upper flange separated from floor by more than 10mm
Straighten and fasten, or renew.
Bowed up by more than 50mm Straighten, or renew.
Cross member flange and web cut.Replacement required!
Cross member web deformed < 75mm.Replacement is required!
12
Fork lift pocket & gooseneck tunnel assembly
Container Inspection Manual
Top plate separation from floor in excess of 10mm or floor screws ineffective
Weld or straighten, or straighten and weld, or insert, or renew.
Web holed, cut torn, or cracked in excess of 500mm or extending into a weld connection
Weld, or straighten and weld, or insert, or renew
Lower flange connection to bottom side rail, holed, cut, torn, cracked extending into web radius
Weld, or straighten and weld, or insert, or section, or renew
Top plate pushed up in excess of 50mm, cut torn or broken
Straighten or weld, or straighten and weld, or insert, or renew
Strap broken, cracked, cut, torn, missing Weld, or straighten and weld, or replace
> 500 mm
Fork lift pocket web cut less than 500 mm.No action required!
Fork lift pocket strap missing.Replacement required!
13
Floor planks and panels
Container Inspection Manual
Gouge greater than 15mm deep irrespective of length Section or renew
Gouge more than 6mm deep and greater than 150mm wide irrespective of length
Section or renew
De-lamination or other damage (affecting floor strength) Replace, if structural integrity is compromised
Difference in height between adjacent planks/panels greater than 10mm
Refasten
Floor plate broken.Replacement required!
Floor de-laminated.Replacement required!
14
Floor fastenings
Container Inspection Manual
Protruding Refasten
Three or more adjacent broken/loose, missing fasteners Refasten or replace
Protruding Floor screw.Refasten is required!
More than three adjacent screws broken off.Replacement is required (also the cross member needs tobe replaced)!
15
Top side rails
Container Inspection Manual
Holed, cut, torn, broken, cracked, deformation exceeding 30mm.
Weld or straighten, or straighten and weld, or insert, or section, or renew.
Top side rail dented in excess of 30 mm.Repair by sectioning the damaged part is required!
Top side rail dented less than 30 mm.No action required!
16
Front and Rear headers
Container Inspection Manual
Holed, cut, torn, broken, cracked, deformation exceeding 40mm.
Weld or straighten, or straighten and weld, or insert, or section, or renew.
Rear header dented less than 40 mm.Repair only when interfering with door operation or broken!
Front header dented in excess of 40 mm.Replacement required!
17
Front and Rear headers
Container Inspection Manual
Holed, cut, torn, broken, cracked, deformation exceeding 40mm.
Weld or straighten, or straighten and weld, or insert, or section, or renew.
Front header flange cut.No action required!
Front header flange cut.No action required!
18
Corner posts
Container Inspection Manual
Holed, cut, torn, broken, cracked Weld or straighten, or straighten and weld, or insert, or renew.
Dents exceeding 20mm Straighten, or insert, or renew.
Bent, bow or deformation, if exceeding outer faces of corner castings by +5mm on end face or +10mm on side face
Straighten, or insert, or renew.
Corner post dented in excess of 20 mm and out of ISO dimensions.Insert required!
Rear corner post dented in excess of 20 mm andinterfering with door operation.Replacement required!
19
Corner posts
Container Inspection Manual
Holed, cut, torn, broken, cracked Weld or straighten, or straighten and weld, or insert, or renew.
Dents exceeding 20mm Straighten, or insert, or renew.
Bent, bow or deformation, if exceeding outer faces of corner castings by +5mm on end face or +10mm on side face
Straighten, or insert, or renew.
Corner post dented less than 20 mm and .No action required!
Front corner post dented in excess of 20 mm.Replacement required!
20
Corner posts
Container Inspection Manual
Examples of acceptableCorner post Inserts
21
Corner posts
Container Inspection Manual
Examples of NOT acceptableCorner post Inserts
22
Corner castings
Container Inspection Manual
Cracked, deformed, broken Replace
Deformation preventing correct twistlock operation Replace
Corner casting broken.Replacement required!
23
Side/front/roof panel incl. header plate
Container Inspection Manual
Dents into cube which reduce the internal width by more than 50mm from the inner corrugation including multiple dents, or 70mm from the floor to the roof inner corrugation
Straighten, or straighten and weld, patch, insert or renew
Holed, torn or cut Weld, or straighten and weld, patch, insert or replaceDents exceeding the outer face or corner casting +40mm
Straighten, or straighten and weld, patch, insert or renew
Side panel out of ISO dimensions by more than 40 mm.Repair by straighten required!
Side panel dented in excess of 50 mm into cubic capacity.Repair by straighten required!
24
Doors
Container Inspection Manual
Holed, cut, torn, broken, cracked component or weld, or deformation affecting security and operation of doors
Weld or straighten, or straighten and weld, or patch, or insert, or renew
Missing/broken or loose parts which affect door operation or watertightness
Replace or refix
Handle retainer bolt loose. Re- fasten required!
Locking bar guide cut but not affecting door operation. No action required!
25
Doors
Container Inspection Manual
Holed, cut, torn, broken, cracked component or weld, or deformation affecting security and operation of doors
Weld or straighten, or straighten and weld, or patch, or insert, or renew
Missing/broken or loose parts which affect door operation or watertightness
Replace or refix
Loose door gasket affecting the watertightness. Re- fasten required!
Door gasket cut and improperly repaired Insert required!
26
J Bars
Container Inspection Manual
If interfering with door operation Weld or straighten, or straighten and weld, or insert
J Bar affecting door operation. Insert required!
J Bar affecting door operation. Insert required!
27
Door hold backs (Tie backs)
Container Inspection Manual
Missing Renew
Door hold back missing. Replacement required!
Door hold back missing. Replacement required!
28
Data plates
Container Inspection Manual
Loose or missing plates Refasten or replace
Data plate (Timber treatment) missing. Replacement required! Example of an intact Hapag-Lloyd Data plate.
29
Lashing devices
Container Inspection Manual
Broken, cracked, missing or non functional Straighten, or weld, or replace
Lashing bar broken. Re-welding required!
Lashing ring not functional.Repair required!
30
Surfaces
Container Inspection Manual
Glue (Sticky) Clean and/or paintOdour, infestation, debris, contamination that can be transferred
Clean and/or remove
Vents blocked, loose, damaged and not weathertight Repair/ replaceGraffiti / foreign markings - offensive/possibly offensive
Repair/remove
Glue and paper rests remaining on inner panel. Removal required!
Rope remaining on Lash ring. Removal required!
31
ISO decals
Container Inspection Manual
Missing or illegible Replace
Container number and weight table missing. Renewal required!
ISO Container Number improperly applied. Remove and replace!
32
Rain gutters
Container Inspection Manual
Damage affecting door operation or exceeding outer face of corner casting +10mm
Straighten or remove
Rain gutter dented, not affecting door operation. No action required!
Rain gutter out of ISO, but not exceeding 10 mm. No action required!
33
Hazardous Label
Container Inspection Manual
Remaining on panels Remove
Rests of IMDG Label remaining on Panel. Complete removal required!
IMDG Label remaining on Panel. Removal required!
34
Roof bows (Open Top Container)
Container Inspection Manual
Holed, cut, torn, broken, cracked Weld, straighten and weld or replace
Missing Replace
Dents into cube which reduce the internal height by more than 70mm
Straighten or replace
Row bows dented in excess of 70 mm and/or holder broken. Straighten and renewal required!
Several roof bows missing. Complete replacement required!
35
Tarpaulin (Open Top Container)
Container Inspection Manual
Cut, holed Repair or replace
Old Tarpaulin patch (not weather tight). Repair required!
Tarpaulin cut. Repair or replacement required!
36
Tarpaulin (Open Top Container)
Container Inspection Manual
Cut, holed Repair or replace
Wrong Tarpaulin not in accordance with Customs Regulations.Replacement required!
Tarpaulin cut. Repair or replacement required!