REEFER CONTAINERS...Repair Manual Reefer Container 6-3. Bottom Side Rail of Aluminum Reefer...

Container RepairReefer Containers

REPAIR MANUAL

FOR

REEFER CONTAINERS

April 2009. [email protected]

mailto:[email protected]

Repair ManualReefer Container

List of Contents.

0 . Scope

0-1. The Purpose of The Manual.

0-2. The Repair Methods

0-3. Structure of the Manual.

0-4. How to Use the Manual.

0-5. How to Update the Manual.

0-6. In case of Doubt.

0-7. Updating of Repair Manual.

1 . General Requirements.

1-1. Quality Standards.

1-2. Ecomonical Criteria.

1-3. Standard Time System (STS)

2 . Materials.

2-1. Steel.

2-2. Stainless Steel.

2-3. Aluminum.

2-4. Fasteners.

2-5. Foam tape, Sealant and PVC Tape.

2-6. Insulation Foam.

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Page 1List of Contents



2-7. Solvent.

2-8. Welding.

2-9. Painting.

2-10. Marking.

3 . General Structure of Reefer Container.

3-1. 40 Foot Aluminum Reefer Container.

3-2. 40 Foot Stainless Steel Reefer Container.

3-3. Rear Frame of Aluminum Reefer Container.

3-4. Rear Frame of Stainless Steel Reefer Container.

3-5. Rear Frame with Insulating.

3-6. Front Frame of Aluminum Reefer Container.

3-7. Front Frame of Stainless Steel Reefer Container.

3-8. Front frame with Insulating.

3-9. Side Assembly of Aluminum Reefer Container.

3-10. Side Assembly of Stainless Steel Reefer Container.

3-11. Side Assembly with Insulating and side Lining.

3-12. Roof Assembly with Insulating of Alu. Reefer Container.

3-13. Roof Assembly with Insulating of SST Reefer Container.

3-14. Base Assembly of Aluminum Reefer Container.

3-15.1 20 Foot Base Assembly of Stainless Steel Reefer Container.






3-16. "T" - Floor Assembly of Aluminum Reefer Container.

3-17.1 "T" - Floor Assembly of Stainless Steel Reefer Container.

3-17.2 "T" - Floor Assembly with Foam of SST Reefer Container.

3-18. Door outer Assembly of Plymetal Door.

3-19. Door outer Assembly of Stainless Steel panel Door.

3-20. Door Foam Assembly of Plymetal Door

3-21. Door Foam Assembly of Stainless Steel panel Door.

3-22. Front Corner connection of Reefer Container.

3-23. Reae Corner connection of Reefer Container.

3-24. Sise Corner connection of Reefer Container.

4 . Inspection and Criteria of Repair.

4-1. Acceptable damage.

4-2. Non - Acceptable damage.

4-3. Wear and Tear.

4-4. Manufacturing Defects.

4-5. Clossary of terms.

4-6. Inspection and Repair methods.

4-6.1 Rails, Headers, Sills.

4-6.2 Posts.

4-6.3 Floor Understructure.

4-6.4 Floor.

4-6.5 Doors.

4-6.6 Panels.

4-6.7 Others.





5 . Decision Diagram for Repair works

5-1. Decision diagram for Top Side Rail of Alu. Reefer.

5-1.1 Decision diagram for Aluminum top side rail.

5-1.2 Decision diagram for Steel top side rail.

5-2. Decision diagram for Top Side Rail of SST Reefer.

5-3. Decision diagram for Bottom Side Rail of Alu. Reefer.

5-2.1 Decision diagram for Aluminum bottom side rail.

5-2.2 Decision diagram for Steel bottom side rail.

5-4. Decision diagram for Bottom Side Rail of SST Reefer.

5-5. Decision diagram for Aluminum Roof Panel.

5-6. Decision diagram for Stainless Steel Roof Panel.

5-7. Decision diagram for Aluminum Side Panels. (exterior)

5-8. Decision diagram for Stainless Steel Side Panels. (exterior)

5-9. Decision diagram for Side Lining. (interior)

5-10. Decision diagram for Interior Top Covers.

5-11. Decision diagram for Aluminum "T" Floor.

5-12. Decision diagram for Alu. Cross Member and Outriggers.

5-13. Decision diagram for Fork Pocket.

5-14. Decision diagram for Gooseneck Tunnel.

5-15. Decision diagram for Sub-Floor. (Alu.Reefer)

5-16. Decision diagram for Corrugated Base Panel)

5-17. Decision diagram for Front Corner Post.

5-18. Decision diagram for Front Header.

5-19. Decision diagram for Front Sill.





5-20. Decision diagram for Rear Corner Post.

5-21. Decision diagram for Rear Header.

5-22. Decision diagram for Rear Sill.

5-23. Decision diagram for Door Assembly.

5-24. Decision diagram for Corner Casting.

6 . Repair Procedure.

6-1. Top Side Rail of Aluminum Reefer Container.

6-1.1 Aluminum Top Side Rail.

6-1.1.1 Straightening.

6-1.1.2 Minor cracks.

6-1.1.3 Top flange cracks.

6-1.1.4 Section.

6-1.2 Steel Top Side Rail.


6-1.2.2 Straightening and Re-weld.

6-1.2.3 Inserting.

6-1.2.4 Section.

6-2. Top Side Rail of Stainless Steel Reefer Container.

6-2.1 Straightening and Re-weld.

6-2.2 Inserting.

6-2.3 Section.





6-3. Bottom Side Rail of Aluminum Reefer Container.

6-3.1 Aluminum Bottom Side Rail.


6-3.1.2 Minor Cracks.

6-3.1.3 Insert and Reinforcement.

6-3.1.4 Section of full profile.

6-3.2 Steel Bottom Side Rail.



6-3.2.3 Inserting.

6-3.2.4 Section.

6-4. Bottom Side Rail of Stainless Steel Reefer Container.

6-4.1 Straightening.


6-4.3 Inserting.

6-4.4 Section.

6-5. Aluminum Roof Panel.(exterior & interior)

6-5.1 Patching without foam repair.

6-5.2 Patching with foam repair.

6-5.3 Section of roof bow.

6-5.4 Large section, Full across-section.

6-6. Stainless Steel Roof Panel.

6-6.1 Rivetted overlay Patches.

6-6.2 Weld Insert or Patch.





6-7. Aluminum Side Panel.(external)



6-7.3 Section of side post.

6-7.4 Large section, Full height section.

6-8. Stainless Steel Side Panel.(external)

6-8.1 Rivetted overlay Patches.


6-9. Side inner lining.(stainless steel lining)

6-9.1 Patching rivetted overlay.

6-9.2 Replace entire height.

6-9.3 MCIT Container.

6-10. Inside Top Corner Covers.

6-11. Aluminum "T" Floors.


6-11.2 Connection Plate at rear end.

6-11.3 Section.(Partial replacement of T-floor)

6-12. Aluminum Cross Members and T-clips.


6-12.2 Stop drilling.

6-12.3 Replacement cross-member and T-clip.

6-12.4 Outriggers.

6-13. Fork-lift Pocket.


6-13.2 Inserting.





6-14. Gooseneck Tunnel.


6-14.2 Inserting.

6-15. Sub-Floor of Aluminum Reefer Container. (base panel)

6-16. Corrugated Base Panel of Stainless Steel Reefer.

6-16.1 Patching by Mono-bolts.


6-16.3 Flat base panel.(MCIT container)

6-17. Front Corner Post.


6-17.2 Inserting.

6-17.3 Replacement entire corner post.

6-18. Front Header.

6-18.1 Welding of patch on front header.

6-18.2 Inserting of front header.

6-18.3 Top Wing Plate.

6-18.4 Clip on device angle.

6-18.5 Replacement of entire front header.

6-19. Front Sill. (Bottom rail)

6-19.1 Insert of front sill.

6-19.2 Replacement of entire front sill.

6-19.3 Front Bottom Wing Plate.





6-20. Rear Corner Post.


6-20.2 Insert of rear post(J-bar)

6-20.3 Replacement of entire rear post.

6-21. Rear Header.

6-21.1 Welding of patch on the rear header.

6-21.2 Inserting of rear header.

6-21.3 Replacement of entire rear header.


6-21.5 Replacement of Cam-Keeper.

6-22. Rear Sill. (Door Sill)

6-22.1 Patching of rear sill.

6-22.2 Inserting of rear sill.

6-22.3 Replacement of entire rear sill.

6-22.4 Rear wing plate.

6-22.5 Replacement of Cam-Keeper.

6-23. Door Assembly.

6-23.1 Patching of door lining and panel.

6-23.2 PVC frame damage.

6-23.3 Door Hard-ware.


6-23.3.2 Section locking Bar.

6-23.3.3 Replacement entire locking bar.

6-23.3.4 Hinge pin.

6-23.3.5 Hinge blades.

6-23.3.6 Brackets, handle,etc.





6-23.4 Door Gasket.

6-23.4.1 Bonding.

6-23.4.2 Section.( outer & inner gasket)

6-23.5 Out-panel delamination.

6-23.6 Door design types.

6-23.6.1 Plymetal out-door type.

6-23.6.2 Fabricated door type1.

6-23.6.3 Fabricated door type2.(MCIQ container)

6-23.6.4 Fabricated door type3.(MCIT container)

7 . Insulation Foam.

7-0. General Repair Policy for Foam Insulation.

7-1. Type of Foam Insulation.

7-2. Calculation of required chemicals.

7-2.1 Injection foaming machine.

7-2.2 Manual foaming.

7-3. Preparation of container for Re-foaming.

7-4. Re-foaming.

7-4.1 Injection of foaming machine.

7-4.1.1 Single injection.

7-4.1.2 Multiple Injection.

7-4.2 Manual Re-foaming.

8 . Photos Damages





0.0 SCOPE.

0-1 The Purpose of the Manual.This manual has been prepared with the intention to inform about box repairs on reefer containers, and to educate the repair shops in using the correct method andprocedure of repair on our containers.

The manual is provided with a set of decision diagrams, which will assist you inchoosing the correct repair.

Additional to this information about types of materials used in the containers isprovided, In general these materials are the minimum requirements for strengthand quality. But better materials may be used if the specified material is not available.

Only the most common repairs are described in this manual. If any repairs are needednot described, please contact Centre Eqiupment Management in Rotterdam.E mail ; [email protected]

0-2 The Repair methods.The methods described in this manual, will all result in proper repairs, If the guidelinesare closely followed.

Most of the methods can be used in any repair shop.However certain tools described may not be found in all repair shops.

If special tools, or alternative methods, are used in your repair shop, they can beused, provided the standard of repair is not less than that which is specified in this manual.

0-3 Structure of the ManualThis manual is built up on a numerical system, with up to four numbers.Each number informs on what level, and where in the manual the chapter belongs.

e.g. 6-3.3.4 etc.

The first digit represents the main level of the manual, and the following numbers the lower levels. The numbers of the lower levels are correspondent to repair code numbers.

The main levels in the manual are structure as shown below :Chapter 0 contains the general information about the manual.Chapter 1 concerns the requirements you shall fulfill.Chapter 2 is general information about the materials and qualities of parts supplied.Chapter 3 is shown General structural of Reefer Container by drawing.Chapter 4 is described inspection and repair criteria.Chapter 5 Is described decision diagram of damagesChapter 6 is described repair procedure.Chapter 7 contains insulating foam.

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0-4 How to use the Manual

When surveying a damage, you should start using chapter 4, to find the criteria ofdamages, Then proceed to chapter 5 for information on how to perform the repair.Finally go to chapter 6 to read about the repairing procedure, and chapter 7 for performing Re-foam of insulation.

0-5 How to Update the Manual

When new chapters or updates of old ones are supplied, these should be placed in themanual, in accordance with the number of the chapter.If it is update, add or remove, and destroy the old pages and insert the new onesin the manual.

0-6 In Case of Doubt

It is not possible to describe every kind of repair you may face. Therefore, you shall always be prepared to make your own decisions, or contact CENEQUEMRTEC @MAERSK.COMFurthermore most repairs as found in practice will differ slightly from the repairsTherefore you shall always

and make sure that the repair methods you chose, will ensure that requirements forstrength and insulation are always fulfilled, and that the container is repaired in the least expensive way.

1.0 GENERAL REQUIREMENTS

1-1 Quality StandardsReefer containers are required to be in good operating condition at all times.When making repairs, only correct materials must be used, and safe procedures mustbe followed. The containers must at all time fulfill the requirements of ISO, the classifi-cation siciety, TIR, TCT, and be capable for transportation of perishable foodstuffin accordance with the ATP regulations.

No materials supplied by the repair shop may be of less good quality than the parts usedoriginally. Please see chapter 2.Materials shall whenever possible be original spare parts.

1-2 Economical criteria

It is important that the methods chosen for the repairs are the least expensive possible.When choosing repair methods, it is therefore important that all possibilities are evaluatedcarefully, in order not to over-repair.

1-3 Standard time System (STS)

You are in possession of a copy of the Maersk Line "Standard Time System". The time consumption described in the STS has been measured by time studies.The STS is based on repair methods as they are described in this repair manual.

… use your common sense …


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2-0 MATERIALS

Reefer containers have internally a decal attached on the door, indicating the type of materials and quality used.

When replacing parts on the container, these materials shall, whenever possible, be used.If the decal is missing, use the folling guidelines when choosing materials for repair,if supplied by the repair shop.

The following is a minimum requirement for strength and quality.

2-1 Steel

All steel parts must be grit blasted to S.A. 2.5 to remove millscale, rust etc. prior to painting.Painting of steel parts must be according to the paint makers guidelines.The steel used must be low alloy, high tensile strength, with the following properties :

Yield point. (minimum) 36 kg/sq.mmTensile Strength (minimum) 48 kg.sq.mm

Steel parts must fit properly to ensure good welding.Welding must be done by shielded metal-arc electrodes, or by gas shielded arc-welding. The welding material must match the steel, as required by the classification society.

Steel parts when in direct contact with aluminum, must be separated by PVC-tape to prevent galvanic corrosion.

2-2 Stainless steel

The stainless steel must be of type 304 or similar.The mechanical properties shall be :

Yield Point 32 kg/sq.mmTensile Strength 50 kg/sq.mm

Muffler stainless steel ;The mechanical properties must be :

Yield Point 32 kg/sq.mmTensile Strength 45 kg/sq.mm

Welding electrodes to be used for welding of these materials, must be of the correct type for this specific welding.


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2-3 Aluminum

All extrusions must be of correct profile, and of alloy 6061-T6.Aluminum panel is type of AA 5052 - 34 or 38 and must be pre-painted to Maersk Sealand standards, and of thickness and strength not less than the original used panel.

2-4 Fasteners

Fasteners are critical for all repairs. Al fasteners must be installed correctly.

Solid rivets are used for fastening for Top / Bottom Tail, Cross-Member, Posts, Al. sheets.

Lock-Bolts are used for fastening for Top / Bottom Tail, Cross-Member, Posts.

Bom-bolts are used for fastening of reefer machine and some of locking rods.

Solid Rivet. ( Aluminum and Stainless steel )

Lock-Bolt. ( Aluminum and Stainless steel , Steel )

Bom bolt.(Steel and Stainless)


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Mono-Bolts are used for fastening for Patching and Side Posts, Al. Sheets,and the parts where able to reach from one side only.

2-5 Foam tape, Sealant and PVC-tape.

All lap joints leading to the foam core of the panels, must have foam tape of sufficientplaced between the lapping parts, to ensure water tightness.

* Foam tape( close cell) must be used between two aluminium sheets.

* PVC (Insulation) tape must be used between steel or stainless and aluminum.All joints between dissimilar materials must have PVC - tape ( Insulation tape) ofsufficient dimension placed between the two parts, to avoid galvanic corrosion.

* All seams of container, leading to the foam core, must have sealant applied.Polyurethane sealant must be applied at exposed area, and butyl sealant or / and foam tape at hidden area

2-6 Insulation Foam

The foam that is used for repairs on reefer containers is of polyurethane type with adesity of 60Kg / ㎡. It consists of two major chemicals ; Polyol and Isocyanate.

For sandwich panel and panels with only few aluminium posts, the strength of thefoam is just as important properties.

Note ;When working with foam production, it is important that the local safetyregulations are strictly followed.

Mono-Bolt. ( Aluminum and Stainless, Steel )


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2-7 Solvent

For degreasing of panels prior to applying the adhesive primer, use only acetone,methylene chloride, or clean thinner.Other solvents may hinder good adhesion.

2-8 Welding.

All welding must be done by qualified welders, using materials (welding rods,s teel sheeting, etc.) equal to those used in the manufacture of original equipment.If the weld materials are unknown, follow the recommendations ;

The welding wire or rod has a minimum yield point of 46 kg/mm or greater and welding should conform to requirements of recognized technical societies such asthe American Welding Society, British Standards, etc. Reference to welding lnspection (published by the American Welding Society) may be helpful.

Integrity of welds usually can be verified easily by visual inspection. A magnifier isuseful. The inspection should determine that the weld is : * watertight and free of porosity

* smooth in appearance (no roughness, weld spatter, etc.) * free of craters * dimensionally accurate (including warpage) * free of undercutting

lnspect to assure full weld penetration. If welding one side of the joint does not achieve full weld penetration, both sides of the joint must be welded.This visual inspection procedure should not supersede more sophisticated procedure.

If needed, for the repairer to be satisfied with weld quality. Non-destructive testingtechniques-based upon magnetic particle, liquid penetrant, radiographic or ultrasoniceddy current-may be used, although they may be beyond the capability of manyrepair facilities. All weld slag and spatter must be removed when using the arc weldingelectrode process.

Completed welds should not be ground smooth unless failure to grind the weld prevent proper mating of the repaired areas.

2-9 Painting.

A repair on a container's steel structure must always be protected by painting with thespecified type of paint, the correct number of coatings and the specified film thickness.

To ensure that repair will last and the appearance of the container will not suffer,good paint work is crucial.


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2-10 Marking.

If decals required by regulations or international standards are missing,defaced, scratched or damaged in other ways. They must be repaired.It is important that these markings are kept in good order. Missing or damagedmarking may result in problems with workers and authorities.

The markings on the container may be divided into three groups ;

A. Markings required by authorities and conventions.

B. Owners identifications

C. Warning details.

The owner's marking(logo) is part of the company's image. To ensure a good presentation this marking must always be kept in a good order.

Unauthorized markings such as graffiti should always be removed either by over-painting or by washing.


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3-0 GENERAL STRUCTURE.

Door

Assembly

Rear

Assembly

Side

Assembly

Roof

Assembly

Front

Assembly

Front

Insulation

Reefer

Machine


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3-1. 40 Foot Aluminium Reefer Container GENERAL STRUCTURE

REA

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3-2 40 Foot Stainless Steel Reefer Container.


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3-3 Rear Frame Assembly of Aluminum Reefer Container.

REAR HEADER

REAR

CORNER

POST

REAR

CORNER

POST

INNE

OUTER

HINGE

LUG

TOP

WING

PLATE

CORNER

PROTECTOR

REAR SILLPROTECTION

CHANNEL

BOTTOM

WING

PLATE


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3-4 Rear Frame Assembly of Stainless Steel Reefer Container.

REAR HEADER

REAR

CORNER

POST

HINGE

LUG

INNE

OUTER

(J-BAR)

REAR SILL

CORNER

PROTECTOR

REAR

TOP COVER

REAR SILL

INNER


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3-5. Rear Frame Assembly with Insulation Foam.

REAR FRAME

SIDE LINING

COVER

ROOF OUTER

PANEL

SIDE

OUT

PANEL

FOAM

TAPE


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3-6 Front Frame Assembly of Aluminum Reefer Container.

FRONT HEADER

TOP WING

PLATE

CLIP ON DEVICE

ANGLE

FRONT HEADER

CORNER

PROTECTOR

FRONT

CORNERPOST

GENSET

FITTINGNUT

COOLING

UNITMOUNTING

NUT

FRONT

SILL

BOTTOM WING

PLATE


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3-7 Front Frame Assembly of Stainless Steel Reefer Container.

FRONT

SILL

FRONT HEADER

CLIP ON DEVICE

ANGLE

GENSET

FITTING

NUT

FRONT

CORNERPOST


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3-8 Front Frame Assembly with Insulation Foam.

AIR SUCTION

SCREEN

FRONT FRAME

BUFFLE PLATE

KICK PLATE

SIDE

LINING

FLOOR

ROOF LINING

AIR SEAL GASKET


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3-9 Side Assembly of Aluminum Reefer Container.

TO

P

SID

E

RAIL

BO

TTO

M

SID

E R

AIL

SID

E

PAN

ELS

BO

TTO

M

WIN

G

PLATE

TO

P

WIN

GPLATE

BO

TTO

N

SID

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AIL

FO

AM

TA

PE

SID

E

STR

ING

ER

SID

E

PO

ST

DO

OR

HO

OK

SID

E P

AN

ELS

FO

AM

TA

PE


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3-10 Side Assembly of Stainless Steel Reefer Container.

SID

E

PO

ST

TO

P

SID

E

RA

ILTO

P

SID

E

RAIL

SID

E

PO

ST

BO

TTO

M

SID

E R

AIL


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3-11 Side Assembly with Insulation Foam and Side Lining.

SID

E L

ININ

G

SID

E L

ININ

G

SID

E O

UT P

AN

EL

BO

TTO

M S

IDE R

AIL

SID

E

PO

ST

SID

E

TO

P

CO

RN

ER

CO

VER


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3-12 Roof Assembly with Insulation Foam of Alu. Reefer Container.

EN

D F

RAM

ER

OO

F P

AN

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SID

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RO

OF L

ININ

GC

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CO

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AN

EL

CO

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ER

CO

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OF B

OW

RO

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TR

ING

ER

RO

OF P

AN

EL


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3-13 Roof Assembly with Foam of Stainless Steel Reefer Container.

CO

RN

ER

CO

VER

RO

OF L

ININ

G

RO

OF P

AN

EL

RO

OF S

TR

ING

ER

RO

OF L

ININ

G


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3-14 Base Assembly of Aluminum Reefer Container.

CR

OS

S-M

EM

BER

S

TU

NN

EL A

SS

'Y

CR

OSS M

EM

BER

"T-C

LIP

"

BO

LSTER

"T-C

LIP

"

BO

LSTER

LO

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M

EM

BER

BO

LSTER

UPPER

MEM

BER

JOIN

T B

OTTO

M S

IDE R

AIL

TO

OU

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ER

JOIN

T B

OTTO

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SID

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AIL

OU

TR

IGG

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"T-C

LIP

"


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BOTTOM SIDE RAIL

FORK-POCKET

BASE PANEL

BOTTOM SIDE RAIL

BASE PANEL


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BOTTOM SIDE RAIL

BASE PANEL

TU

NN

EL A

SS

'Y

LOAD MEMBER

TUNNEL BOLSTER

TUNNEL

HORIZONTAL

MEMBER


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3-16 "T" - Floor Assembly of Aluminum Reefer Container.

REAR

GU

TTER

CO

NN

EC

TIO

N

T-FLO

OR


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3-17.1 "T"-Floor Assembly of Stainless Steel Reefer Container.

CONNECTION PLATE

REAR GUTTER

"T"-FLOOR

FLASHING SIDE

(SIDE COVER)

FRONT FAN


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3-17.2 "T"-Floor Assembly of Stainless Steel Reefer Container.

"T"-FLOOR

ASSEMBLY

FLASHING

SIDE

BASE

ASSEMBLY

REAE

GUTTERCONNECTION

PLATE


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3-18 Door Assembly of Plymetal Door.(AL. Reefer)

SIDE

AL.

FRAME

HINGE

BLADE

DOOR

PANEL


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3-19 Door Assembly of Stainless Steel Reefer Container.

REAR

ASSEMBLY

HINGE

PIN

DOOR

LINING

DOOR

OUTER

PANEL

GASKET

DOOR

OUTERPANEL

HINGE

BLADE

DOOR

OUTER

PANEL

DOOR

LINING

GASKET


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3-20 Door Foam Assembly with Plymetal Door.

DOOR LINING

DOOR

OUTER

DOOR

OUTER

L/SIDE

CENTER

DOOR INNER

GASKET

DOOR PVC

FRAME

DOOR

OUTER

DOOR

OUTER

GASKET

DOOR INNER


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3-21 Door Assembly of Stainless Steel Reefer Container.

GASKET DOOR INNER

GASKET

DOOR

INNER

DOOR

INNER

DOOR

INNER

DOOR

OUTER PANEL

DOOR

OUTER

DOOR

OUTER


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3-22 Front Corner Connection of Reefer Container.

Front top

Lining(cover)

Roof

Lining

Roof

outer panelFront Header

Top PVC

connector

Out Side

Panel

Front

Corner Post

Pvc connector

Inside Lining

Air baffle

plate

Front

lining (cover)

spring

Front sill

Kick plate

(Btm Air guide)

front

Pvc connector

TOP

SIDE

BOTTOM

OUTER

GASKET


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3-23 Rear Corner Connection of Reefer Container. Base panel

TOP

SIDE

BOTTOM

Rear HeaderRoof panel

Roof Lining

Top Lining

PVC connectorRear

corner post

Out side

panel

Side Lining

Rear Lining

PVC connector

Rear sillBase panel

"T"-Floor


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3-24 Side Corner Connection of Reefer Container.

TOP

BOTTOM

Roof Panel

Top Side Rail

Roof Lining

StringerlTop Side Cover

Bottom Side Rail

Out side

Panel

Side Lining

Top Side Rail

Base PanelFlashing side

Rear sillBase panel


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Flashing side

(Btm side cover)


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4 INSPECTION OF DAMAGE AND

CRITERIA OF REPAIRS

W

L

△D

△D

△D

H


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4-0 Inspection and criteria of repair.

* These criteria are designed for use at all container inspections.

* The criteria should not vary between an in-service and on/off hire survey inspection and should be accepted on a universal basis by shipping lines, and container operators supporting these criteria for all general world-wide container interchanges.

* Items not specifically detailed in the criteria are covered by this general introduction only if they require repair

* The tolerances/permitted damages listed are not the minimum necessary to meet basic safty 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 particular repair location.

* When parts have to be replaced on a container, material of the same or better quality, has to be used.

4-1 Acceptable damage.

This is defined as damage that is not to be repaired and includes ;

* All flange damage except damage to weld connections.

* Deformation of structural members up to ISO +10mm on the side face of the corner casting and ISO +5mm on the end face of the corner casting.

* Previous repairs should not be reworked unless the structural integrity of the container is compromised or it is unsuitable for cargo.

4-2 Non-Acceptable damage.

This 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 custom Convention (TIR) is violated.

* Any cracks or deformation in corner casting.

* There is reduction in the internal height dimension by more than 60mm and/or the internal width dimension by more than 50mm.


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* The container is unsuitable for cargo.

* Cracks in welds are present and/or corrosion, not due to paint failure loss of structural integrity is present.

* A condition which causes loss of water tightness or thermal tightness is present.

4-3 Wear and tear.

This is defined as unavoidable change or deterioration of the condition of the containerbrought about by routine use and includes ;

* General paint deterioration.

* Deterioration of door gasket and fittings.

* Deterioration of door fixings arising from deterioration of doors, which is not affecting the water tightness.

* Floor de-laminated resulting from routine cargo loading and unloading cycles, ref. the 25 percent rules.

4-4 Manufacturing defects.

This is defined as difference to builder's specification with regard to materials,workmanship and factory guarantees.

* Manufacturing defects or suspected manufacturing defects are to be reported.

4-5 Glossary of Terms.

Holed : Perforated through the entire thickness.

Cut : Separeted through the entire thickness of material along a sharp edge.

Cracked : Having a break, which penetrates the entire thickness of material and causes it to split slightly. In addition, If a weld between two different matal components has any separation in it, even if the entire thickness of the weld material is not penetrated, that weld is considered "cracked"

Torn : Pulled apart by ripping or rending through the entire thickness of the metarial.

Broken : Fractured or shattered into two or more separate pieces.


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Bend : Sharp deflection in a component, which causes a permanent change in the original geometry of the component over some portion of its length or width.

Dent : A localised depression in a panel or structural member made by pressure or an impact or blow that causes a sharp change in the sharp of a component over a limited area of the component.

4-6 Inspection and Repair methods.

4-6.1 Rails, Headers and Sills.

Front and Rear sills & headers

Weld or straighten, or vice versa or insert, or section, renew

and strength.

50mm or ISO +10mm

* Cracks or tears which

* Deformation in excess of 30mm or ISO +10mm Weld or straighten, or vice versa

or insert, or section, renew

* Holed,cut,torn,broken,

COMPONENT DAMAGE RECOMMENDED REPAIR METHODS


Top side rail

* Heavy corrosion causing reduction in metal thickness

cracked


* Holed,cut,torn,broken, cracked

Bottom side rail

* Heavy corrosion causing reduction in metal thickness and strength.

* Deformation in excess of 50mm

cracked

* Deformation in excess of

extend into web radius

* Interference with door closure securing and/or water tighten.


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with fitting of a clip-on genset.

* Broken component and/or weld, except flanges.

4-6.3 Floor Understructure

* Web holed,cut,torn,or

Front and Rear sills & headers


* Strap broken, cracked,

* Deformation which interferes

4-6.2 Posts


Corner posts


cracked

* Dents exceeding 25mm

* Bend,bow or deformation, if exceeding outer faces

+10mm on end face.

Corner castings

* Deformation preventing

Replace

correct twist-lock operation


* Cracked,deformed,broken.

of corner castings by +5mm on end face or

* Interference with door operation,securing, water tightness or thermal tightness.


cracked in excess of

Fork lift pocket& Goose neck

tunnel assembly


a weld radius.

* Web deformation below line into corner casting

500mm or extending into

cut, torn, missing


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rated from floor by more

* Web deformed in excess

50mm or below line of corner casting

Straighten, or renew of 75mm

* Web upper flange sepa-

* Web holed,torn,broken, Weld or straighten, or vice versa or insert, or section, renew cracked,cut or missing

Straighten and repair or renew

Cross Member

* Holed - up to 20mm To be sealed. - above 20mm To be repaired by glue patch.

Base Panelincluding

Corrugations

than 10mm

* Bowed up by more than

* Broken component or weld Repair / renew

* Cut,torn,or cracked To be repaired by glue patch. (upto 200mm) above 200mm by patch.

* Missing or loose parts Repair / renew

* Missing drains(kazoo's) Renew

* Delamination from insulating Open up, remove old foam, clean foam by more than 25% of surface apply primer and re-foam. total area

* Deformation such as bend, bowed, dent, etc. in excess

To be repaired. of 50mm dept or below line of corner castings or internal height is reduced by more than 30mm


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4-6.4 Floor.


* Holed, cut, torn, broken or

least 4 adjacent T- bars and if

* Delamination of T-floor from Open up and remove old foam, clean

cargo.

* T-bar bent or crushed if at

more than 150mm in length and more than 30mm side ways.

To be repaired,

* T-bars flange protrudes To be straighten and/or welded. into cargo space.

Weld or straighten, or vice versa or insert, or section, renew cracked.

* Broken T-section / weld

surface, apply primer, and re-foam.

25% of total area. - instert base filler as anchors. foam base insulation exceeds

* Contamination from previous To be cleaned / removed

To be repaired,

* Blocked drain hole Clean, renew

* Broken, bent upwards or Only to be repaired if operation missing. affected.

* Broken welds Re-weld

* Missing Renew if needed.

* Bent No action

Floor

T-section floorreinforcement(connection

plate)

Lashing bars


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in total area

Free-up / loosen

cracked component or

affect door operation or Renew or Refit parts(incl.gasket) which



* Missing/broken or loose

weld, or deformation affect -ing security and operation of doors

* Seized, frozen,etc.

* Cracked or deformed Weld or renew, straighten

* Seized, frozen or stiff Free-up / loosen

Weld or straighten, or straighten and weld, or insert,

operation

water tightness

* If interfering with door


Locking bars

J-Bar

Doors assembly incl. hardware

and hinges

4-6.5 Doors

* Torn or deformed Renew or straighten

* Any deformation affecting doorStraighten, repair or renew operation or watertightness

* Exposed foam Repair by patch/section

* Holed, cut, torn, cracked or Weld, repair or seal if exposed delaminated ply metal door

* Loose or missing door gasket No action

* Delamination of panel from Open up, remove old foam,

water leaks. burned or showing light or leaks, no action. If not, repair, renew

Hinge pins

Keepers / Cams

Handle

External /Internal

foam inslation more than 25% apply primer, re-foaming

Door gasket

Miscellaneous* loose or missing data plates Fasten or renew

corner tabs.

* Holed, cut, torn, cracked or Minor damages, if no light and water


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* Holed, cut, torn, broken. To be patched / inserted.

Roof panel

Corner protection plate & header

extensionplates.

bow, dent etc. more than 50mm in any direction

* Delamination of panels from Open up, remove old foam, clean

* Deformation such as bend, Straighten or re-weld or insert.

foam insulation by more surface, apply primer, re-foaming. than 25% of the total area.

exceed ISO +10mm or interior height reduced by 30mm

* Deformation such as bend, etcTo be repaired. in excess of 50mm which

tightness.

* Any condition causing loss of To be repaired. water tightness or thermal

* Exposed foam To be patched/sectioned

component or weld.

cracked panel.* Broken or punched


* Holed, cut, torn, broken or

* Dents exceeding the outer To be repaired. face of the corner casting

* Delamination exceeding 25% Open up, remove old foam, clean of the total area. surface, apply primer, re-foaming.

+ 40mm.

tightness.

* Any condition causing loss of To be repaired. water tightness or thermal

by more than 50mm

To be patched / sealed* Deformation into the cube straighten, repair which reduces internal width

4-6.6 Panels


* Holed,cut,torn,broken, Weld or straighten, or vice versa or insert, or section, renew cracked panel.

Exterior / interiorpanels

interior covingflashing

* Exposed foam.


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Foam insulation

Improper repair

Graffiti

Surface

Indentification

House marking/ logos

see separate chapter

* Exposed foam.(interior or

* Odour

* Less than 0.5㎡ if house

* Structurally sound No action

* Waterlogged To be drained / dry out

25% of the total area.* Delamiantion- any panel To be repaired if area exceeds

To be pached / sealed exterior)

* Glue (sticky) To be renewed / re-painted

To be cleaned / removed

or possible offensive marking* Any political, religious, sexual To be cleaned / removed

* If more than 0.5㎡. To be cleaned / removed

No action logo not affected

missing and/or patchedTo be renewed / re-painted

marking/mumbers and /or data plates excl. houselogos

4-6.7 Others


* Loose, missing or defaced To be fastened / re-newed

identification(mandatory)

* If not readable and/or loose,


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* Paint attack due to corrosive cargoes or spilage.

the floor cracks between floor boards or within side -wall corrugations.

4-6.8 Cleanliness


Interior and Exterior

*Labels, including hazardousRepair

cargo labels.* Contamination(hazardous If condition could threaten human life or

or portentially hazardous) health, container may be rejected at gate.

Otherwise, segregate container and

contact redelivery agent to establish type

of contaminant and appropriate treatment.

Do not attempt to repair until instructions

Repair

are received.* Tape over ventilatore Repair

* Materials(other than normalRepair dust and dirt) stuck to

caulking

* Organic cargo residues,

Repair beans,grain,etc, within

* Debris or dunnage in

Repair excess of what would normally remain after a sweep out

* Transferable stains, moldRepair

or fungus(except tire marks)

Repair glue, including sticky tape and sticky adhesive residue

* Loose or not fully adheredRepair

tape or other material.

Interior, includingwalls,ceiling and

floor

* Infestation(except non-Repair

transferable mold)

* Patch(of any size) of sticky


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If not obviously related to carriage of cargo, Repair

Repair water

* persistent odor

Repair metal/wire straps,cable, chains,string,rope,etc. left on bars,rings,walls, ceilings,floors,etc,

* Graffiti

Exterior

* Graffiti

* Cargo securement devices,

* Condensation or standing

Repair

* Spillage on exterior whichRepair renders the marking required

by regulation illegible



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5-0 Decision Diagram for Repairing works.


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5-1 Decision Diagram for Top Side Rail of Aluminum Reefer.

5-1.1 Decision Diagram for Aluminum Top Side Rail.

START

Any broken or

cut, cracked

Deformed

more than 30mm

Deformed

ISO +10mm

Is it possible

to straighten

Any separating

and/or rivet loose

to lead water leaks

The damage affecting

top flange only

No Repair

Rivets and

sealing(see chapter

6-1.1.2)

Straighten

(see chapter

6-1.1.1)

Section

(see chapter6-1.1.4)

Repaired by

splicing

(see chapter

6-1.1.3)

No Yes

No

No

No

No Yes

Yes

Yes

No

Yes

Yes


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5-1.2 Decision Diagram for Steel Top Side Rail.

START

Any broken or

cut, cracked

Deformed

more than 30mm

Deformed

ISO +10mm Is it possible

to straighten

Any separating

and/or rivet loose

to lead water leaks


top flange only

No RepairRivets and

sealing

Straighten


Section

(see chapter

6-1.2.4)

Straighten

& weld(see chapter

6-1.2.2)

No Yes

No

No

No

No Yes

Yes

Yes

No

Yes

Heavy corrosion

affecting strength

No

Yes

Insert


The damage

affecting

upper & lower part

YesNo


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5-2 Decision Diagram for Top Side Rail of Stainless Reefer.

START

Any broken or

cut, cracked

Deformed

more than 30mm

Deformed

ISO +10mm

Is it possible

to straighten


more than 50% ofvertical profile

No RepairStraighten

Section

(see chapter

6-2.3)

Straighten

& weld

(see chapter

6-2.1)

No Yes

No

No

No

Yes

Yes

Yes

No

YesHeavy corrosion

affecting strength

No

Insert

(see chapter6-2.2)

Possible to

straighten and Re-

weld

YesNo


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5-3 Decision Diagram for Bottom Side Rail

5-3.1 Decision Diagram for Aluminium Bottom Side Rail.

START

Any broken or

cut, cracked

Deformed

more than 50mm

Deformed

ISO +10mm

Is it possible

to straighten

Any separating

and/or rivet looseto lead water leaks

damaged on

horizontaldirection only

No Repair

Rivets and

sealing

(see chapter

6-3.1.2)

Straighten


Section

(see chapter

6-3.1.4)

Repaired by

splicing(see chapter

6-3.1.3)

No Yes

No

No

No

No Yes

Yes

Yes

No

Yes

Yes

damage affecting

upper & lower web

Yes No


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5-3.2 Decision Diagram for Steel Bottom Side Rail.

START

Any broken or

cut, cracked

Deformed

more than 30mm

Deformed

ISO +10mm

Is it possible

to straighten

Any seperating

and/or rivet looseto lead water leaks

No RepairRivets and

sealing

Straighten


Insert

(see chapter

6-3.2.3)

Straighten

and Re-weld(see chapter

6-3.2.2)

No Yes

No

No

No

No Yes

Yes

Yes

Yes

Heavy corrosion

affecting strength

No

Yes

Is it possible to

straighten and re-weld

damage affecting

upper & lower web

Yes

Section

(see chapter

6-3.2.4)

YesNoNo


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5-4 Decision Diagram for Bottom Side Rail of Stainless Steel Reefer.

START

Any broken or

cut, cracked

Deformed

more than 30mm

Deformed

ISO +10mm

Is it possible

to straighten

No RepairStraighten

(see chapter

6-4.1)

Insert

(see chapter6-4.3)

Straighten

and Re-weld

(see chapter

6-4.2)

No Yes

No

No No Yes

YesYes

Heavy corrosion

affecting strength

No

Yes

Is it possible to

straighten and re-weld

damage affecting

more than 50% of

vertical profile

Yes

Section

(see chapter6.4.4)

YesNoNo


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5-5 Decision Diagram for Aluminum Roof Panel.

START

Any broken panel

delaminated more

than1.0M(logitudinal),

1.5M(the width)

No Yes

Yes

deformed

more than 50mm

deformed

ISO +10mm

internal height

reduced more than

damage affect

rail / header

distance to the

panel edge

less than 50mm

distance to the

another patch

less than 50mm

consider patch

to edge

consider patch

also cover old

patch

damage less than

+25mm in depth

and +300mm in

broken roof bow

more than two(2)

damage affect

more than 75%of the width

No RepairGlue Patch

(see chapter

6-5.1)

Section

all across

(see chapter

6-5.4)

Patch

with foam(see chapter

6-5.2)

Section

roof bow

(see chapter

6-5.3)

Repair

with rail/header

Yes

Yes

Yes

Yes

Yes

Yes

No

No

No

Yes

Yes

No

No

No

No

Yes

No


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5-6 Decision Diagram for Stainless Steel Roof Panel.

START

Any broken panel

delaminated more

than

1.0M(logitudinal),

1.5M(the width)

No Yes

Yes

deformed

more than

50mm

deformed

ISO +10mm

internal height

reduced

more than

damage affect

rail / header

distance to the

panel edge

less than 50mm

distance to the

another patch

less than 50mm

consider patch

to edge

consider patch

also cover old patch

damage less than

+25mm in depth

and +300mm in

damage more than

500 x 500mmdamage affect

more than 75%

of the width

No RepairGlue Patch

(see chapter6-5.1)

Section

all across

Patch

by welding

(see chapter

6-6.2)

Patching

by rivets(see chapter

6-6.1)

Repair

with

rail/header

Yes

Yes

Yes

Yes

Yes

No

No

No

Yes

Yes

No

No

No

No

Yes

No

No

Yes


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5-7 Decision Diagram for Alimunum Side Panel(exterior).

START

Any broken panelNo YesNo

delamianted

1.2M(longitudinal)

and 50% in height

internal width

reduced more than

50mm

deformed

ISO +40mm

damage with

rail / post of end framebroken side post

distance to the

edge less than

150mm

consider

patch tothe edge

distance to the

another patch

less than

consider patch

also cover

old patch

damage affect

more than 75%of the height

damage more

than25mm(depth)

No RepairRepair with

rail / post

Patch without

foam(see chapter

6-7.1)

Section

full height

(see chapter

6-7.4)

Patch

with foam

(see chapter

6-7.2)

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

No

No

No

No

No

Section

side post

(see chapter

6-7.3)


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5-8 Decision Diagram for Stainless Steel Side Panel(exterior).

START


delamianted

1.2M(longitudinal)and 50% in height

internal width

reduced more than50mm

deformed

ISO +40mm

damage with

rail / post of end framedistance to the

edge less than150mm

consider

patch to

the edgedistance to the

another patch

less than

damage affect

more than 75%

of the height

damage more

than25mm(depth)


rail / post

Patch by

rivets

(see chapter

6-8.1)

Section

full height

Patching by

welding(see chapter

6-8.2)

Yes

Yes

Yes

Yes

Yes

No

No

No

No

No

Glue Patch

(see page3

chapter5)

damage affect

more than 300 x 300mm

No

Yes

Yes


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5-9 Decision Diagram for Side Lining(interior)

START


delaminated more

than1.0M(longitudinal)

internal width

reduced

more than50mm

any water and/or

air leaks

damage

with cover

distance to edge

less than 150mm

distance toanother

patch less than

150mm

consider patch

also cover

old patch

consider

patching reachto edges

damage affect

75% of height


covers

Section

full height

(see chapter

6-9.2)

Patch

with foam(see chapter)

6-9.1)

Sealing,

riveting

No

No

No

Yes

Yes

No

No

Yes

Yes

Yes

Yes

Yes

Cut Al. scuff liner

Insert welding

(see chapter6-9.3)

Yes


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5-10 Decision Diagram for Interior Top Cover

START


Is there water-

leaks

and/or

air leaks

Is it possible

to repair bysealing or/and

rivets

foam exposed

broken inner cover

broken outer

cover only

No Repair

No

Sealing,

replace rivets

cut less than

width 5mm

and length 150mm

Sealing,

Section

(see chapter6-10)

No

No

No

Yes

Yes

Yes

Yes

No

Yes

Yes

No


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5-11 Decision Diagram for Aluminum "T" floor.

START

Any broken or cracksNo YesNo

Bent more than

30mm in wide and

150mm in length

possible to

straightening

Bent more

than 4 rows

Cut or crack

on the base plateor vertical web

damaged more than

150mm or 2 rows

Any missing or

broken on connection

plate

at rear end

No RepairStraighten

(see chapter

6-11.1)

Replace or

Reweld

(see chapter

6-11.2)

Section

(see chapter6-11.3)

No Repair

No

No

No

No

Yes

No

Yes

Yes No

YesYes

Yes

Delaimation more than 25%

No Yes

Yes

Repair

(see chapter

6-11.4)


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5-12 Decision Diagram for Al. Cross-Members and Outrigers.

START

Any broken or cracks

on the cross-member

No

YesNo

deformed more than

75mm

bowed up more than

50mm

possible to

straighten

without heat.

crack less than 30mm

within 200mm of the ends,

crack, broken

on T-clip

Repair

(see chapter

6-12.4)

Straighten

(see chapter6-12.1)

Drill stop

holes(see chapter

6-12.2)

Replace

T-clip

Replace

crossmember(see chapter

6-12.3)

outrigger damageYes

No

No Repair

Yes

Yes

Yes

Yes

Yes

No

Aluminum Cross

Member

Yes


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5-13. Decision Diagram for Fork-pocket.

START

Any holes, or cut

in the fork-pocket

Web deformed

below of

Internal height

reduced more than

30mm

Web holes,cut,cracked

length +500mm or

extends

into weld connection

Straps broken,

crack, cut

Is it possible to

straighten ?

Is it possible to

straighten and weld

damage affecting

entire cross sectionor more economical

No Repair

Straighten

(see chapter

6-13)

Straighten

and weld

Insert

(see chapter

6-13)

Replace

component

(see chapter

YesNo

Yes

Yes

Yes

YesYes

No

No

No

No

No

Yes

Yes

No

No Repair

YesNo


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5-14 Decision Diagram for Gooseneck Tunnel.

START

Any holes, or cut

in the Goosenecktunnel ass'y

Web deformed

below of

Internal height


Web holes,cut,cracked

length +500mm orextends

into weld connection

Is it possible to

straighten ?

Is it possible to

straighten

and Re-weld

damage affecting

entire cross section or more economical

No Repair

Straighten

(see chapter

6-14)

Straighten

and weld

Insert

(see chapter6-14)

Replace

component(see chapter

YesNo

Yes

YesYes

Yes

No

No

No

No

No

Yes

Yes


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5-15. Decision Diagram for Sub-Floor(Aluminum Reefer).

START

Any holes, or cut

in the Sub-floor

Web deformed

below of C/castingOR

deformed exceeding

50mm

Internal height

reduced more than

30mm

Holed

more than

20mm

No RepairRepair

or renew

YesNo

Yes

No

No

Sealing

Glue

Patching

(see chapter

6-15)

Patching with

foam repair

(see chapter

6-15)

Cuts,torn

more than 200mm

YesNo

Any parts missing

or loose

No

Yes

Yes

No

Yes


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5-16. Decision Diagram for Corrugated Base Panel.

START

Any holes, or cut

in the Sub-floor

Web deformed

below of C/casting

OR

deformed exceeding

50mm

Internal height


Holed

more than

20mm

No RepairRepair

or renew

YesNo

Yes

No

No

Sealing

Glue

Patching

(see page3

chapter5)

Patching by

rivets(see chapter

6-16.1)

Cuts,torn

more than

200mm

YesNo

Any parts missing

or loose

No

Yes

Yes

No

Yes

damage more

than 1M x 1M

Patching by

welding

(see chapter

6-16.2)

Yes No


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5-17. Decision Diagram for Front Corner Post.

START

Any cuts, brokenYesNo

deformed exceeding

outer face of corner

casting

+5mm on end face OR

+10mm on side face

dents exceeding

25mm

possible to

straighten

damage distance

within 300mm of

corner casting

consider

reach to casting

damage crossed

entire section

No RepairStraighten

(see chapter

6-17.1)

Insert

(see chapter

6-17.2)

Replace

entire post

(see chapter

6-17.3)

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No


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5-18. Decision Diagram for Front Header.

START

Any cuts, broken

Yes

No

Yes

deformed exceeding

50mm

damaged

clip on device

damage on front

joining

face with machine

damage affect

+50% ormore economical

damage depth

less than 25mm

damage on

top wing plate

No Repair

Straighten

orReplace

(see chapter

6-18.4)

Patching

(see chapter

6-18.1)

Insert

with foam

(see chapter

6-18.2)

Replace

entire

header

(see chapter

6-18.5)

Straighten

or Replace

(see chapter

6-18.3)

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes


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5-19. Decision Diagram for Front Sill.

START

Any cuts, broken

Yes

No

deformed

more than 50mmdamage on

bottom wing plate

damage on

underneath only

damage affect

+50% ormore economical

No Repair Patching

Insert

with foam(see chapter

6-19.1)

Replace

entire sill(see chapter

6-19.2)

Straighten

or Replace

(see chapter

6-19.3)

No

No

No

Yes

Yes

Yes

Yes


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5-20. Decision Diagram for Rear Corner Post.

START

Any cuts, brokenYesNo

deformed exceeding

outer face of corner castion

+5mm on end face or

+10mm on side face

dents exceeding

25mm

Interference door

operation

damage "J"-bar only

possible to

straighten

No Repair

Insert

J-bar

(see chapter

6-20.2)

Replace

(see chapter

6-20.3)

Straighten

(see chapter

6-20.1)

Yes

Yes

Yes

Yes

Yes

No

No

No

No

No


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5-21. Decision Diagram for Rear Header

START

Any cuts, broken

Yes

No

Damage

roof face onlydeformed exceeding

50mm

Interference

door operation

damage

cam-keeper

Damage depth

less than 25mm

Damage depth

more than 25mm

or

damage on

gasket & keeper

contacted area

No RepairRepair keeper

(see chapter

6-21.5)

Patching

(see chapter6-21.1)

Insert

(see chapter6-21.2)

Replace

(see chapter6-21.3)

Wing plate

(see chapter

6-21.4)

Entirely replacing is

more economical

Yes

Yes

Yes

Yes

Yes

Yes

No

No

No

No

Yes

No


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5-22. Decision Diagram for Rear Sill.

START

Any cuts, broken

Yes

No

deformed exceeding

50mm

Interference

door operation

damage

cam-keeper

damage on

gasket & keeper contacted area

No RepairRepair keeper

(see chapter

6-22.5)

Damage

base part only

Wing plate

(see chapter

6-17.4)

Entirely replacing is

more economical

Patching

(see chapter

6-22.1)

Insert

(see chapter

6-22.2)

Replace

(see chapter

6-22.3)

Yes

Yes

Yes

Yes

Yes

YesNo

No

No

No


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5-23. Decision Diagram for Door Assembly

START

YesAny holes or cuts on

the inner or outer

panel

Patching

inner liningor outer pnael

(see chapter

Any holes or cuts on

the PVC frame

loosed gasket

Sealing

Section

PVC frame

(see chapter

6-23.2)Any damage on the

door hard-ware

Straighten

or sectionor replace

(see chapter

6-23.3)

Yes

Yes

Yes

No

No

No

No

Any damage

on the gasket

Bonding or

section orReplace

(see chapter

6-23.4)

Any other deformation

affecting door

operation

Straighten or

sealing, renew

No Repair

No

No

Yes

Yes

Delamination

on outer door panel

No

Fix outer door

by bolting.

(see chapter

6-23.5)

Yes


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5-24. Decision Diagram for Corner Casting.

START

Are there any Cracks or

Broken or deformed ?

No Yes

Is there any deformation

preventing correct twist-lock operation ?

Replace entire

corner castingNo Repair

No

Yes


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6-0 Repair Procedure


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6-1. Top Side Rail of Aluminum Reefer Container.

6-1.1 Aluminum Top Side Rail.

The type of repair recommended for damaged aluminium top rails depends on the nature and extent of the damage and its impact on the container's structuralstrength, thermal integrity, watertightness and cosmetic appearance ;

No need repair,

if no cracks.

repaired by

insert of top

repaired by

section of full

profile.


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* Minor dents, no crack, in horizontal flange of the top rail are not to be repaired.

* Small dents, bows and other minor damage may be repaired by straightening without heat.

* Small cuts or cracks up to 25mm in length may, under certain condition, be repaired by stop drilling holes and sealing for water tightness.

* Larger cuts and gouges may be repaired by stop-drilling and reinforcement with a double plate.

* Bent top flanges may be repaired by reinforcing with an angle splice, or installing an insert and double plate.

* Cuts, gouges and breakage that include or extend above the panel rivets line may be repaired by installing an insert reinforced with a double plate.

* Major damage requires a full profile section, which must be attached to the original rail with splice plate.


Whenever possible, straighten dents, bulges and bows by mechanical means.NEVER use heat. Be careful not to crack the rail when straightening. If the rail happencrack during straightening, the cracks must be repaired by inserting or section, etc.


Minor cuts or cracks up to 25mm in length and 3mm in width, and not within 1M of the corner fitting, may be repaired by straightening without heat, drilling stop holes atboth end of the cracks or cuts, and apply sealing for water-tightness.

If any rivets missing or loose, the rivets must be replaced by using mono-bolts or poprivets.(3/16" or 1/4" diameter)

* Cracks within 1M of the corner fitting require insert repair.

6-1.1.3 Top flange cracks.

It is not necessary to repair minor bents if not cracks. If the cracks are longer than 25mm, an insert must be installed with a reinforcement double plate in the top rail flange.

A. Remove the rivets from roof along the damaged area of the top rail and release roof panel from top rail flange.

B. Cut out the damaged area of the flange back to the web.


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C. If there is a crack in the damaged area, drill a 3mm stop hole at end of the cracks. Fill the cracks and holes with sealant.

D. Prepare a reinforcement angle to extend 75mm beyond each end of the damaged area. Place it in the cut-out area on top of the flange of the reinforcement angle and clamp the both end parts.

E. Fasten the reinforcement angle to top side rail by using of 1/4" Al. mono-bolts. The rivets pitch is 25mm each distance.

F. If necessary, repair roof panel with a patching.

G. Apply foam tape or sealant on the reinforcement top surface which will be overlapped with roof sheet.

H. Rivet roof sheet to reinforcement top flange and original top rail by using of solid rivets.

I. Re-foam any cavity if required.

J. Clean repaired area and apply selfleveling sealant on the roof rivets head.


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Foam tape or sealant

inbetween

overlap

75mm

25mmSoild rivets or

1/4" Mono-bolts


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6-1.1.4 Section

If the damage is full vertical profile or bottom part of the top side rail, The damage must berepaired by installing a section piece of full profile of the top side rail.

* major damage requires a full profile section, which must be attached to the original rail with splice(replaced) plate.

* The length of each rail section must be a minimum of 1.2M. * No splice(section piece) can be made less than 1.0M from either end frame.

* The splices of the top rail and bottom rails on the same side of the container must be offset by 0.6M minimum.( the side post distance is 0.6M )

* The distance between the splices of top and bottom rails on the opposite side of the container must be offset by 0.6M minimum.

* Only two(2) sections(4 sets of the splicing plates) are allowed to be made on each top or bottom rail each time a container is repaired. When more than two splices are necessary on a top or bottom rail, then extend the length of the replacement section limiting the repair to two(2) splices per rail.

* Direct contact between dissimilar metals, such as steel and aluminum, must be prevented with suitable insulating(barrier) tape.

* Fasteners must not protrude beyond normal ISO dimension tolerances.

* All foam removed during repairs must be replaced with new foam of equal or greater.

* Splice and double plate must be made of 6061-T6 aluminum. Steel plates must be not used.

* Repairs using splice or double plate must be separated by a minimum distance of 1M.

* All double / splice joints and fasteners must be sealed to prevent water-leaks.

* Double plates must be at least equal in thickness to the material being reinforced, and must have the greatest cross-sectional area within space constrains of the rail configuration.

* Section must begin and end midway between side wall posts.

* If a cut must be made within 1M of of a corner fitting, extend the section to the fitting.

A. Mark the area of the rail to be removed.

B. Remove the fasteners securing roof and side wall to the top rail. If the section extends to the end frame, the fasteners securing top rail to wing plate must be removed.


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C. Cut out a piece of roof sheet, big enough to enable you to work on the back side of the top rail.(ACCESS OPENING)

D. Cut out damaged top rail. The cutting line must be at center of side posts.

E. Remove the foam along the damaged section and the ends of the remaining rails to enable mounting of splice plates.

F. Prepare replacement section piece to the length require. ( Minimum length is 1.2M )

G. Place the replacement section with splice on position and clamping. ( in the overlapping area , apply foam tape or sealant inbetween splice and top rails)

out side

back-side

==


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H. Drill the fastener's holes and fasten the lock-bolts or solid rivets. * the lock-bolts or solid rivet diameter must be equal of 7.9mm(5/16") or bigger. * the material of the fastener is 2024 or 7075 T-6 for lock-bolts and collars, or 2117 - T4 for solid rivets. * the splice(double) plate must be made of 0.6M in length.

I. Fasten the roof sheet and side post by using solid rivets.

J. Re-foaming repaired area and clean, sealing.

outside

splice

inside

splice

25mm 50mm

600mm

distance must be kept original design

Lock-bolt or

Solid rivets+7.9mm

diameter

solid rivets

+6.4mm

diameter

Access

opening

The joint must be at middle of

distance of side posts.


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* If the damage is located within 1M of the corner fitting, the section piece

must be replaced from end of top rail.

METHOD 1. The end frame maybe must be cut-out for fastener access hole approximately

100mm x 200mm in top header, using a disc cutter. Do not use a flame torch, It makse burn the foam during cutting.

METHOD 2. If the repair shop has 9.8mm diamater steel or stainless mono-bolt, the replacement section can be fastened by using 9.8mm mono-bolts with PVC washer.

The PVC wahser make seperating Al. top rail and steel mono-bolts, therefore the PVC

washer must be used.(see the sketch)

(Aluminum mono-bolt does not have strength, do not use Al. bolts on the wing plate)** NOT NECESSARY TO MAKE ACCESS OPENING BY CUTTING END FRAME **

PVC

cut out end frame

to access the toolduring fastening.


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6-1.2 Steel Top Side Rail.


Whenever possible, steel top rails of refrigerated containers should be repaired bystraightening without heating, Heat may be used only when the rail cannot be straightened without heat. Damage that cannot be repaired by straightening alonemay be repaired by a combined procedure of straightening and welding or by installing an inserting or sectioning, If the rail can not be repaired by inserting or sectioning, It must be replaced. If it is necessary to apply heat to assist in straightening, the steel should be heated only to a dull cherry-red color(650℃) and only in the damage area.


To repair splits, cuts, tears or pin holes when the original profile can be restored,1) straighten the torn area. 2)Weld the edges of the cut material. 3) Clean, mask, prime and top coat the repair area.

No repair,

if not crack

Section

Insert


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6-1.2.3 Inserting.

When damage cannot be repaired by straightening, an insert may be installed.

* Insert must be a minimum of 150mm in length.* If an insert would end within 150mm of another vertical rail weld, it must be extended to that weld.* If an insert in a top side rail would end within 300mm of a corner fitting, it must be extended to the fitting.* Insert must have the same cross-sectional profile as the original rail.* Insert must be fitted flush with the original rail.

A. Determine the length of rail to be removed and mark where the cut is to be made.

B. Remove fasteners securing the top rail to side panel or roof panel as required.

C. Using disc cutter, cut out damaged part. And remove foam, lining, other parts. Be careful not to damage adjoining components. Straighten the remaining rails edges if bent. Clean and smooth all cut edges with a disc grinder.

D. Cut to size, clean and fit replacement insert. The insert must fit flush with the original rail. Allow no more than 2mm clearance between adjoining surfaces.

E. Weld replacement insert to original rail.

F. Clean the welded area and prime , top coating.

G. Apply foam tape and barrier tape which is joined panels.

H. Fasten the top side rail and side panel or roof panel.

I. Re-foaming where was removed during repair works.

J. Apply sealant(polyurethane) the repair area.

INSERT

W

Remove foam


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6-1.2.4 Section.

Damage that cannot be repaired by straightening or inserting may be repaired by replacing the damaged section of rail or by replacing the entire rail. When installinga replacement section, the entire cross-section of the rail must be removed.

* Replacement material must be of the same specification, thickness and profile as the original.* Section must be at least 150mm in length.* If a section would end within 150mm of another vertical rail weld, it must be extended to that weld.* If a section in a top side rail would end within 300mm of a corner fitting, it must be extended to the fitting.

A. Determine the length of original rail to be removed. Mark where the cut are to be made.

B. Remove fasteners attaching top rail, side posts, roof and side panels as required.


D. Cut to size, clean and fit replacement section or new rail into position. The section must fit flush with the remaining rail profile. Allow no more than 2mm clearance between adjoining edges.

E. Position new rail or section and tack weld into place. Check alignment to ensure thar ISO dimension tolerances are maintained.

F. Continuously weld the replacement section to original top rail. * the weld must be penetrated full thickness. * No need to grind welding protruded bead on the rail to make flush. * Clean welding slags, spatters, burn paint, make smooth the surface(no sharp)

G. Apply primer and top coating.

H. Apply foam tape and barrier tape to prevent electrolytic corrosion.

I. Re-attach the roof panel and side panels. ( If necessary, repair side and/or roof panel by patching )

J. Re-foaming repaired area.

K. Apply sealant.( polyurethane sealant )


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Remove foam not to burn

during welding

Solid rivet on the top rail

blind rivet on the patch

25mm

fully welding

penetration


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* If the damage is located within 1M of the corner fitting, the section piece must be replaced from end of top rail.

METHOD 1. The end frame maybe must be cut-out for fastener access hole approximately 100mm x 200mm in top header, using a disc cutter. Do not use a flame torch, It makse burn the foam during cutting.

METHOD 2. If the repair shop has 9.8mm diameter steel or stainless mono-bolt, the replacement section can be fastened by using of 9.8mm mono-bolts with sealant

(Aluminum mono-bolt does not have strength, do not use Al. on the wing plate)** NOT NECESSARY TO MAKE ACCESS OPENING, CUTTING END FRAME **

cut out end frame

to access the tool

during fastening.

Weld

SEALANT

Weld


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6-2 Top Side Rail of Stainless Steel Reefer.

Whenever possible, steel top rails of refrigerated containers should be repaired bystraightening without heating, Heat may be used only when the rail cannot be straightened without heat. Damage that cannot be repaired by straightening alonemay be repaired by a combined procedure of straightening and welding or by installing an inserting or sectioning, If the rail cannot be repaired by inserting or section, It must be replaced. If it is necessary to apply heat to assist in straightening, the steel shouldbe heated only to a dull cherry-red color(650℃) and only in the damage area.


To repair splits, cuts, tears(50mm in length, 3mm in width, 13mm in depth) or pin holes when the original profile can be restored,

A. weld or straighten & weld the damage.

B.Clean, mask, prime and top coat the repair area.

Section of top side rail,

Patching of roof & side panel.

If no crack, less

than 13mm dents, no need to repair.


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6-2.2 Inserting.




B. Using disc cutter, cut joining welds with top side rail, roof panel or side panel.

C. Using disc cutter, cut out damaged part. And remove foam, lining, other parts. Be careful not to damage adjoining components. Straighten the remaining rails edges if bent. Clean and smooth all cut edges with a disc grinder. * the horizontal weld seam must not be welded at formed edge(bending line)

D. Cut to size, clean and fit replacement insert. The insert must be beveled 45˚and fitted flush with the original rail. Allow no more than 2mm clearance.


F. Weld roof panel and side panel to top side rail.

G. Clean welded area, remove welding slags, burn paint,etc.

H. Apply primer by brush and top coating.


Insert top side rail.


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6-2.3 Section.


* Replacement material must be of the same specification, thickness and profile as the original.* Section must be at least 150mm in length.* If a section would end within 150mm of another vertical rail weld, it must be extended to that weld.* If a section in a top side rail would end within 300mm of a corner fitting, it must be extended to the fitting.


B. Cut welds joining with top side rail, roof panel and side panel.


* If good welder who can weld thin stainless steel panel(0.8mm) is available in repair shop, cut entire profile section of top rail as figure 1. on next page.

* If thin stainless steel panel cannot be welded in repair shop, the edge of top rail may be left about 15mm to weld with replacement section as figure 2. on next page. It is easy to weld.


* the replacement section and original top rail must be beveled 45˚ at edges prior to joining to give full welding penetration.

E. Position new rail or section and tack weld into place. Check alignment to ensure the ISO dimension tolerances are maintained.


G. Weld roof panel and side panel to top side rail.

H. Clean welded area, remove welding slags, burn paint, etc.


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I. Apply primer and top coating.



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6-3. Bottom Side Rail of Aluminum Reefer Container.

6-3.1 Aluminum Bottom Side Rail.

The type of repair recommended for damaged aluminium bottom rails depends on the nature and extent of the damage and its impact on the container's structural strength,thermal integrity, watertightness and cosmetic appearance ;

section

reinforce

lower flange

reinforce

upper flange

stop holes

and sealing

reinforce

lower flange

no repair

if no crack


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* Minor dents, no crack, in horizontal flange of the bottom rail are not to be repaired.

* Small dents, bows and other minor damage may be repaired by straightening without heat.

* Small cuts or cracks uo to 25mm in length may, under certain condition, be repaired by stop drilling holes and sealing for water tightness.

* Horizontal larger cuts up to 150mm and gouges may be repaired by stop-drilling and reinforcement double plate.

* Bent top flanges may be repaired by reinforcing with an angle splice, or installing an insert and double plate.

* Major damage requires a full profile section, which must be attached to the original rail with splice plate.


Whenever possible, straighten dents, bulges and bows by mechanical means.NEVER use heat. Be careful not to crack the rail when straightening. If the rail happencrack during straightening, the cracks must be repaired by inserting or section, etc.Welding or heating aluminum rail components NOT allowed.


Minor cuts or cracks up to 25mm in length and 3mm in width, and not within 1M of the corner fitting, may be repaired by straightening without heat, drilling stop holes atboth end of the crack or cut, and apply sealing for water-tightness.

If any rivets missing or loose, the rivets must be replaced by using mono-bolts or poprivets.(3/16" or 1/4" diameter)

* Cracks within 1M of the corner fitting require insert or section repair.

6-3.1.3 Insert and Reinforcement.

** Upper part damages.Large cracks, cuts, gouges in the upper half of the bottom rail may be repaired by stop drilling holes, reinforcing with a double plate and sealing.

A. Cut a rectangular access opening into the side panel above the damaged portion of the rail to allow installation of a double plate. And remove foam from behind damaged area.

B. Prepare aluminum double plate, at least same thickness of the original.


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C. Drill stop hole at end of cracks or cuts.

D. Fit the double plate behind the damaged part and clamp in place.

E. Drill the holes for 7.9mm(5/16") diameter and fasten the solid rivets.

F. Apply appropriate polyurethane sealant to the cracks, holes.

G. Reattach side panel to bottom rail.(patching)

H. Re-foaming damaged area and clean.

access opening to insert

rivet tool stop

holes

double

plate

double

plate

38mm

install double plate

inside of bottom

cut out side panel

solid

rivets


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** Lower web part damages.

Cuts, gouges, bends, or breakage in the lower web and flange of the bottom railmay be repaired by installing a double plate over the damaged area.* The area of damage must not extend above lower edge of the rail more than 50% of the lower web dimension.* The area of damage must not exceed 600mm in length.* If the damage exceeds either of the limits listed above, the rail must be repaired by sectioning.* Splice and double plate must be made of 6061-T6 aluminum, Steel plate must not used.* Splice and double plate must be fitted tightly against the original rail profiles.* All double plate/splice joints must be sealed to prevent water-tightness.

A. Remove crossmember end clip's rivets from one crossmember on either side of the damage, and from any crossmembers within the damaged area.

B. Prepare a double plate from 6061-T6 aluminum greater than or equal in thickness to the bottom rail lower web. * The double plate width must have the maximum width possible that will still enable it to fit inside the lower web. * The double plate must be long enough to span and include the end clip fastener for one crossmember on either side of the damage.

C. Position the double plate on the outer face of the bottom rail lower web and clamp into place.

D. Drill the fastener holes for a minimum 9.5mm diameter and fasten the solid rivets or lock-bolts and its collars.

double plate

50mmstop holes

25mm


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50mm

double plate

25mm - 38mm


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6-3.1.4 Sectioning of full profile.

More extensive damage should be repaired by replacing the damaged section of rail,or by replacing the entire rail.

* Section must be at least 1M long.* Section must be a minimum of 1M apart.* Full-profile sections are not permitted within 1m of a corner fitting.* Splice plate must extend and fastened to a crossmember "T"-clip on both sides of the splice.* The fastener should be 9.5mm diameter solid rivet or lock-bolt with collar.* Splice and double plate must be made of 6061-T6 aluminum, Steel plate must not used.* Splice and double plate must be fitted tightly against the original rail profiles.

* All double plate/splice joints must be sealed to prevent water-tightness.* Direct contact between dissimilar metals, such as steel and aluminum, must be prevented with suitable insulating(barrier) tape.* Fasteners must not protrude beyond normal ISO dimension tolerances.* All foam removed during repairs must be replaced with new foam of equal or greater.

A. Mark the section of the rail to be removed. Remove fasteners securing side panel and crossmembers to bottom rail. If the section extends to the end frame, fasteners securing the rail to the end frame.

B. make vertical cuts with a disc cutter midway between crossmembers. Remove the damaged section. Straigthen or replace any damaged side wall panels as required.

C. Support the container and check ISO dimension and remove foam.

D. Prepare a replacement section of identical thickness, specification and profile to the the rail. The section should be fitted into existing bottom rail with not more than 2mm clearance at each end.

E. Attach the replacement section to the original rail with the splice plates at each end. Drill holes in the replacement section and splice plates, "T"-clip holes.

F. Fasten replacement section and splice, original bottom rail and sealing.

G. Patch side panel and attach to bottom rail by mono-bolts with foam tape.

H. Re-foaming the repaired area and clean and additional sealing if necessary.


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Replacement

section

upper double plate

(install inside)

lower double plate

(install outside)

cut-out side panel at

both joint to allow tool using.

25 - 38mm50mm

25 - 38mmlock-bolt or

solid rivet

(9.5mm)

solid rivet

(7,8 or 9.5mm)


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6-3.2 Steel Bottom Side Rail.




To repair splits, cuts, tears or pin holes when the original profile can be restored,1) straighten the torn area. 2) Weld the edges of the cut material. 3) Clean, mask, prime and top coat the repair area.

straighten, if no

crack and

deformed +30mm

insert

lower flange

or

straighten & Re-weld

section

full profile


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6-3.2.3 Inserting.




B. Remove fasteners securing the bottom rail to side panel or crossmember as required.

C. Using disc cutter, cut out damaged part. And remove foam, other parts. Be careful not to damage adjoining components. Straighten the remaining rails edges if bent. Clean and smooth all cut edges with a disc grinder.




G. Apply foam tape and barrier tape which will be joined panels.

H. Fasten the bottom side rail and side panel, if necessary


J. Apply sealant(polyurethane) the repair area.


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6-3.2.4 Section.


* Replacement material must be of the same specification, thickness and profile as the original.* Section must be at least 150mm in length.* If an insert would end within 150mm of another vertical rail weld, it must be extended to that weld.* If an insert in a bottom side rail would end within 300mm of a corner fitting, it must be extended to the fitting.


B. Remove fasteners attaching bottom rail, side posts, crossmembers and side panels as required.

C. Using disc cutter, cut out damaged part. And remove foam, other parts. Be careful not to damage adjoining components. Straighten the remaining rails edges if bent. Clean and smooth all cut edges with a disc grinder.


E. Position new rail or section and tack weld into place. Check alignment to ensure that ISO dimension tolerances are maintained.


G. Apply primer and top coating.

H. Allpy foam tape and barrier tape to prevent electrolytic corrosion.

I. Re-attach the side panels and cross-members. ( If necessary, repair side panel by patching )


K. Apply sealant.( polyurethane sealant )


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welding

(full penetration)

steel or stainless

lock-bolts(9,5mm)


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6-4. Bottom Side Rail of Stainless Steel reefer




To repair splits, cuts, tears(50mm in length, 3mm in width, 13mm in depth) or pin holes when the original profile can be restored, 1) weld or straighten & weld the damage.

2) Clean, mask, prime and top coat the repair area.

Damaged

upper flange

Damaged

lower flange

Weld small cut, crack


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6-4.3 Inserting.


* Insert must be a minimum of 150mm in length.* If an insert would end within 150mm of another vertical rail weld, it must be extended to that weld.* If an insert in a top side rail would end within 300mm of a corner fitting, it must be extended to the fitting.* Insert must have the same cross-sectional profile as the original rail.* Insert must be fitted flush with the original rail at upper web(flange)* Overlap patching maybe inastalled by welding if damage is lower web only.


B. Cut out damaged bottom rail and side panel or base panel if damaged together. Use disc cutter when cutting, do not use flame torch.

C. Remove foam from damaged area. Be careful not to damage adjoining components. Straighten the remaining rails edges if bent. Clean and smooth all cut edges with a disc grinder.

D. Cut to size, clean and fit replacement insert. The insert must fit flush with the original rail at upper flange. Allow no more than 2mm clearance between adjoining surfaces. * If damage is lower flange only, overlap patching can be installed by welding.



G. Re-foaming where was removed during repair works.

insert patching


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M C I T Container

6-4.4 Section.


* Replacement material must be of the same specification, thickness and profile as the original.* Section must be at least 150mm in length.* If an insert would end within 150mm of another vertical rail weld, it must be extended to that weld.* If an insert in a bottom side rail would end within 300mm of a corner fitting, it must be extended to the fitting.


B. Cut out damaged bottom rail and side panel or base panel if damaged together. Use disc cutter when cutting, do not use flame torch.

C. Remove foam from damaged area. Be careful not to damage adjoining components. Straighten the remaining rails edges if bent. Clean and smooth all cut edges with a disc grinder.


* If good welder who can weld thin stainless steel panel(0.8mm) is available in repair shop, cut entire profile section of bottom rail as figure 1. on next page.

* If thin stainless steel panel cannot be welded in repair shop, the edge of bottom rail may be left about 15mm to weld with replacement section as figure 2. on next page. It is easy to weld.


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E. Weld replacement insert to original rail. * the weld must be penetrated full thickness. * No need to grind welding protruded bead on the rail to make flush. * Clean welding slags, spatters, burn paint, make smooth the surface(no sharp)


G. Re-foaming where was removed during repair works.

M C I T Container

Figure 1.


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Figure 2.

straighten remaining

rail edge.


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6-5 Aluminum Roof Panel.(exterior& interior)

Damage to aluminum panels can be repaired by installing riveted overlaying patches.If the damage is too severe or extensive to be repaired by patching, the entire panel should be replaced. Procedures for patches vary according to the location of thedamaged area. Requirements for patches on the middle portion of a panel differ from those next to panel joints or panel edges.

* No welding of the aluminum patches or roof bow is permitted.* Replacement panel or patches must be made from aluminum material at least 2mm thickness, material specification and surface finish and color as the damaged panel.* Wet or damaged foam must be replaced when patching or installing a replacement panel.* Aluminum patches should be cleaned and coated with adhesive primer before they are installed.* Paches must be properly riveted to the remaining panel. Rivets must be of a water-resistant type.* Minimum rivet diameter is 4.75mm(3/16").

patch with

foam patch

(glue patch)without

foam repair

section roof bow,

if broken

Section

full width


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Small cuts less than 25mm depth and 300mm length can be repaired by installingaluminum patch or glue patch. It is not necessary to cut out damaged portion.

A. Clean the surface to be attached patching by slovent, sandpaper if necessary.

B. Dry the foam and surface if the damage is wet.

C. Fill up the dents or/and cut area by using of any kind of sealant to make flat the surface.

D. * Place the glue patch and press it to give good adhesion.(GLUE PATCH) ( see chapter 6-5, page3. for INSTRUCTION OF GLUE PATCH ) * Apply sealing on the entire surface of patching. (AL. PATCH)

E. Place the patch and rivets. If butyl sealant is squeezed out, if used butyl in item C. the butyl must be removed in the outside.

F. Apply polyurethane sealant along the patch.

** In case of using glue patch, no need rivet and sealing around glue patch.

** If the surface can not be made flat or cleaned, use mormal aluminum patch with sealing or foam tape and rivet 4.7mm diameter, 25mm pitch distance.

The surface to be attached glue patch

must be cleaned and flat.

glue patch

oraluminum patch

by blind rivets


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1. Make your choice of size of patch, allowing approx. 50mm overlap, and mark the patch area.

2. Be sure that the damaged area is flatten out for any protrusions.

3. Clean throughly the whole area, with rotating steel wire brush or abrasive paper, and clean the grinded area with alcohol, thinner or any concentrated non-oil base cleaner.

4. In case damaged area is not flat, the hole has to be filled with sealer prior patch is installed.

5. Remove backing paper and press the patch into the clean area, use a wooden block and a big hammer to ensure total adhesion, especially along all edges and corrugations.

6. No sealer is needed along the patch edges.

7. The patch can be applied down to 15℃- 18℃,but it is recommendable, in cold climates to use e.g. a hairdryer, prior the patch is pressed in place.

8. The spare patches must be stored in warm locations, wrapped up in plastic bag or airtight packing approx. 21-41℃.

9. The normal curing time is Approx. 24 hours at over 21℃.

** THE PERFORMANCE OF GLUE PATCHES, DEPEND ON THE CLEANING !!!

APPLICATION INSTRUCTION FOR Glue patch.

push down any over surface.

fill up the dimple(damage)

patching

at least 50mm


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Large cut more than 25mm in depth and 300mm in length must be filled up the cavityby urethane foaming after patching.

* Do not patch over corrosion or electrolytic damage. * If damage extend to within 50mm of the roof edge or header plate, extend the patch to the edge of the roof or header plate and use original fastener holes. * Patch must adhere to the underlying foam. * Do not drill through or rivet roof boes when securing patches.

A. Check damaged foam condition, If the foam is dry, it is not necessary to cut-out. If the damaged foam is wet, the damaged panel must be cut-out and remove the wet foam.

B. Mark the damaged area where to be cut and overlapped with patch. * the overlapping area must be flattened the surface.

C. Cut - out damaged panel and remove foam damaged.

D. Prepare patching and apply adhesive primer on the interior surface. * A rectangular patch must be overlapped by 50mm with original panel.

E. Apply a continuously bead of sealant to the patch at overlapping area or attach foam tape around inner perimeter of patch.

F. Place the patch and drill 5.0mm holes and rivets. * the rivet diameter is minimum 4.7mm and the distance of rivets is 25mm. * the edge distance center of rivet to edge of panel is 13mm. * the rivets must have water-tight aluminum.

G. Foaming the cavity of damage under securing the patch by pressing. * Be careful not to bulge the patch when foaming.

H. Clean the patch and working area and apply urethane sealant all around patch and apply self-leveling sealing to the exterior line of the rivets to seal fully.

I. If roof decals were damaged, replace as required.

remove wet and broken foam ;

place patch with foam tape.

foam

tape


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rivet and foaming

re-

3/16" Al.

blind rivets

the patching area must be

pressed before and during

the patching area

must be pressed

before and during

foaming.

polyurethane sealant

around patch

overlap

50mm

25m

selfleveling sealer


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6-5.3 Section of Roof Bow.

If aluminum roof bows are broken completely more than two, the bows must be straighten or section or connection broken parts, or replaced.

A. Cut out roof pane at broken bow and cut-out broken portion.

B. Remove foam to access the tool and hands when repairing bows.

C. Section roof bow with reinforcement plate.

D. Continue the repair works patching, following to chapter 6-3.2

6-5.4 Large Section, Full cross-section.

Replacement of a panel section may be repaired when this is more econimical than patching or the damage affect more than 75% of the width and 1.0M in longitudinal.If out-panel and inner-lining are damaged together, the outer and inner panel must be repaired by sandwich foam panel or replacing panels, then foaming.

Al. more than 3mm thick plate

solid rivet or mono-bolt

distance 25mm


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A. Remove fastener securing with damaged panel.

B. Cut out damaged panel. Be careful not to damage top side rail, inner top cover. If inside lining does not cut and can be straightened, straighten the lining.

C. Remove wet foam and broken foam, old sealant, tape, etc.

D. Prepare Al. panel and apply adhesive primer on the interior surface. * A rectangular patch must be overlapped by 50mm with original panel.

E. Apply a continuously bead of sealant to the patch at overlapping area or attach foam tape around inner perimeter of patch. * Apply barrier tape wherever steel and aluminum might come in contact.

F. Place the patch and drill 5.0mm holes and rivets. * the rivet diameter is minimum 4.7mm and the distance of rivets is 25mm. * the edge distance center of rivet to edge of panel is 13mm. * the rivets must have water-tight aluminum. * solid rivets must be used at top side rail. * Do not drill through the roof bows.*G. Foaming the cavity of damage under securing the patch by pressing. * Be careful not to bulge the patch when foaming.

H. Clean the patch and working area and apply urethane sealant all around patch. Apply liquid sealant on the rivets head, mono-bolts and solid rivets.

Foam tape

replace damaged panel,


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the patching area must be pressed before and during foaming.

25mm3/16" Al.

mono-bolts

soild rivets


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IF SANDWICH FOAM PANEL IS AVAILABLE IN REPAIR.


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sandwich foam panel

foam tape

3/16" mono-bolts

3/16" mono-bolts

self-leveling sealing

MANUAL FOAMING

after installed sandwich foam panel.


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6-6. Roof Panel.(Stainless steel external)

Damage to stainless steel exterior panels can be repaired by installing riverted patches,or welded inserts or patches, Rivetted patches are allowed on stainless steel panel up to 500mm one side length

Welding thin stainless steel is difficult to perform without warping the steel and/or damaging foam and sealants. This work should be performed only by qualified stainless steel welders equiped with the proper specialized materials.

* Patches should be of the same specification as the original panel. * Patches must be watertight, fit tightly against the panel, and coated adhesive primer or bonding on the interior surface and adhere to the underlying foam. * Use caulking for final seal on riveted overlay patches. * If the damage is too severe or extensive to be repaired by patching, the entire panel should be replaced.

weld patching

and re-foam.

install patching

by rivets

weld patching full width

and re-foaming


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6-6.1 Riveted Overlay Patches.

If damage affect up to 500mm x 500mm on roof panel, the damage can be repaired byinstalling overlap patch using of mono-bolts.( stainless steel 3/16" )

A.* Prepare the damaged panel surface so the area surruonding the damage is flat and distortion-free, and will allow the overlay patch to fit tightly to the surface.

* If wrinkles or creases cannot be flattened adequately, or the damage depth is more than 37mm(1.5"), cut away with tinsmith shears, disc cutter or jig saw. Leave a rectangular hole with straight, flat, even edges.

B. Carefully examine the foam for damage and moisture. Remove out the damaged foam if required.

C. Prepare a patch of material of identical specification, grade and gauge to the original panel. The patch must overlap the perimeter of the damaged area by 50mm on all sides. Cut the patch with straight edges and apply foam adhesive primer to the foam side of the patch.

D. Apply a continuous bead of sealant between the line of rivet holes and the edge of the patch. Be sure there are no breaks or gaps in the sealant. Alternatively, use 50mm wide 1.2mm thick foam tape around the inner perimeter of the patch.

E. Position the patch and apply even pressure to expel excess sealant. * If damaged portion is not cut-out and the depth is less than 37mm, the damaged area must be flatened( fill up) by sealant before installing patch. * the excess sealant must be removed, especially butyl must not be exposed.

F. Fasten the patch to roof panel by using of stainless steel mono-bolt. * the distance is 25mm pitch.

G. Foam any cavity if damaged area was cut away.

H. Spray painting, primer and top coat by air spray.

I. Apply polyurethane sealant to all round edges of the patch.


If the damage to exterior roof panel exceeding 500mm x 500mm, the damage must be repaired by welding of patch or insert.

A. Mark the area to be cut out, allowing an extra margin beyond the damage. The cut- out area must be rectangular or square, with straight edges. Using a disc cutter, cut away the damaged area. Grind the cut edges smooth.


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C. Prepare the replacement insert or patch from material of the same specification, gauge and profile as the original panel.

* If you are installing an insert, weld backing strips must be used to protect the foam insulation. Cut strips 30mm wide and place around the entire perimeter of the cut-out area.

* Patches must overlap the existing panel by 13mm.

* The foam behind welding seam line must be removed and cleaned. D. Weld the insert or patch.

E. After continuous weld were completed, drill 6.5mm holes for injection foam and air escape.

F. Foaming under properly securing the panels during injection and foam swalling.

G. When the foam is cured completely, close holes by 1/4" stainless steel mono-bolts.

H. Clean and painting.

Patching with

mono-bolts

Patching with

welding

Patching

must clean before installing of patch

25mm

welding

welding


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REPLACE DAMAGED PORTION BY USING OF SANDWICH FOAM.

If the danaged is exterior and interior toghter and sandwich foam is available,

A. Mark the damaged area, and cut out damaged panel, outer & inner by straight line.

B.Prepare replacement sandwich foam. * the foam thickness must be same and more than 60Kg/㎥ of density. * 50mm overlay for inner lining Aluminum and 30mm for outer panel. * Back plate can be used for welding at outer panel joint.

C. Install back plate at outer panel joint if necessary.

D. Clean the outer panel where will be welded with sandwich foam. The welding line and back plate must be cleaned completely by soft sand drinder.

E. Apply sealant or foam tape on the inner lining overlap joint.

F. Place(Insert) replacement sandwich foam on location.

G. Weld outer panel and rivets inner lining overlap joints.

H. Foam the joining area.

I. Clean and painting(blasting, primer, top coat)

50mm

30mm

must

clean must

cleansealing or

foam tape

welding

rivets

back


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6-7 Aluminum Side Panel (external)

Damage to aluminum panels can be repaired by installing riveted overlaying patches.If the damage is too severe or extensive to be repaired by patching, the entire panel should be replaced. Procedures for patches vary according to the location of thedamaged area. Requirements for patches on the middle portion of a panel differ from those next to panel joints or panel edges.

* No welding of the aluminum patches or side post is permitted.* Replacement panel or patches must be made from aluminum material of the same thickness, material specification and surface finish and color as the damaged panel.* The patch for side panel must be pre-painted.* Wet or damaged foam must be replaced when patching or installing a replacement panel.* Aluminum patches should be cleaned and coated with adhesive primer before they are installed.* Patches must be properly riveted to the remaining panel. Rivets must be of a water-resistant type.* Minimum rivet diameter is 4.75mm(3/16") between panel to panel and 6.35mm(1/4") between panel to side post.

small cut

Glue patch

Patch &

Refoam

Section

side post

Replace

full height


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Small cuts less than 25mm depth and 300mm length can be repaired by installingaluminum patch or glue patch. It is not necessary to cut out damaged portion.

A. Clean the surface to be attached patching by slovent, sandpaper if necessary.

B. Dry the foam and surface if the damage is wet.

C. Fill up the dents or/and cut area by using of any kind of sealant to make flat the surface.

D. * Place the glue patch and press it to give good adhesion.(GLUE PATCH) * Apply sealing on the entire surface of patching. (AL. PATCH)

E. Place the patch and rivets. If butyl sealant is squeezed out, if used butyl in step C. the butyl must be removed in the outside.

F. Apply polyurethane sealant along the patch in case of patch with rivets.

** In case of using glue patch, no need rivet and sealing around glue patch. (see chapter 6-5. page 3 )

** If the surface can not be made flat or cleaned, use mormal aluminum patch with sealing or foam tape and rivet 4.7mm diameter, 25mm pitch distance.

Small cut

Clean

surface,

fill up cavity and

attach glue patch

or Al. patch with

rivets

sealing


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Large cut more than 25mm in depth and 300mm in length must be filled up the cavityby urethane foaming after patching.

A. Check damaged foam condition, If the foam is dry, it is not necessary to cut-out. If the damaged foam is wet, the damaged panel must be cut-out and remove the wet foam.

B. Mark the damaged area where to be cut and overlapped with patch.

C. Cut - out damaged panel and remove foam damaged if foam is wet or broken.

D. Prepare patching and apply adhesive primer on the interior surface. * A rectangular patch must be overlapped by 50mm with original panel.

E. Apply a continuously bead of sealant to the patch at overlapping area or attach foam tape around inner perimeter of patch.

F. Place the patch and drill 5.0mm holes and rivets. * the rivet diameter is minimum 4.7mm and the distance of rivets is 25mm. * the edge distance center of rivet to edge of panel is 13mm. * the rivets must have water-tight aluminum.

G. Foaming the cavity of damage under securing the patch by pressing. * Be careful not to bulge the patch when foaming.

H. Clean the patch and working area and apply ployurethane sealant all around patch.

Large cut,

broken foam and wet


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Remove damaged panel and wet & broken foam

Install patching Injection foaming here

with securing panel not to make bulging

overlap 50mmedge distance

edge to rivetMin. 13mm

urethane

sealing

25mm

Foam

tape


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6-7.3 Section of Side Post.

If aluminum side posts are broken and can not be straightened , the posts must be section or connection broken parts.Welding or heating to straighten is nor permitted in the aluminum post.

A. Cut out damaged portion of side post.

B. Remove foam to access the tool and hands when repairing post.

C. Section side post with reinforcement plate.

D. Continue the repair works patching, following to chapter 6-4.2

Aliminum plate

Min.3mm thickness

side panelsolid rivet or

mono-bolt

25mm

solid rivet or

mono-bolt

FOAMING

HERE


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6-7.4 Large Section, Full Height-section.

Replacement of a panel section is done when this is more economical than patching,or the damage affect more than 75% of the height and 1.2M in longitudinal.If out-panel and inner-lining are damaged together, the outer and inner panel must be repaired by sandwich foam panel or replacing panels, then foaming.

A. Remove fastener securing with damaged panel.

B. Cut out damaged panel. Be careful not to damage top side rail, bottom rail. If inside lining does not cut and can be straightened, straighten the lining.

C. Remove wet foam and broken foam, old sealant, tape, etc.

damaged more than

75%

of height and one

side panel(1.2M)

Remove damaged

panel & foam.

50mm50mm

INSIDE

OUTSIDE


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D. Prepare Al. panel and apply adhesive primer on the interior surface. * A rectangular patch must be overlapped by 50mm with original panel.

E. Install side post according to original design.

F. Apply foam tape to the aluminum panel at overlapping area.

G. Place the panel into position and rivets each corner and side post by mono-bolts. * If inside lining was removed, the fastener must be used by solid rivets. * If inside lining was not removed, the fastener must be used by 6.4mm diameter mono-bolt on the side post and top. Bottom rail. * the rivets distance must following original distance of the container. * the edge distance center of rivet to edge of panel is at least 13mm.

H. Foaming the cavity of damage under securing the patch by pressing. * Be careful not to bulge the foaming panel when foaming.

I. Clean the patch and working area and apply polyurethane sealant all around panel.

J. Attach any decal if necessary.

Top & Bottom cover

may be removed by

disc cutter.

The covers can be joint by

butt and polyurethane sealing

when new panel installing.

Foam tape.

Replacement stainless panel

Replacement aluminum panel


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Al. mono-

Stainless

mono-bolts

(3/16")

INJECTION FOAMING

Foam tape.

Replacement Al. panel

Replacement stainless panel


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IF SANDWICH FOAM PANEL IS AVAILABLE IN REPAIR.


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Replacement sandwich foam panel

Foam tape

Manual foaming


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6-8. Side Panel.(Stainless steel external)

Damage to stainless steel exterior panels can be repaired by installing riverted patches,or welded inserts or patches, Riveted patches are allowed on stainless steel panel up to 300mm one side length If the repaired area includes a corrugation, the rivets can be placed inside of corrugations at vertical lines.Welding thin stainless steel is difficult to perform without warping the steel and/or damaging foam and sealants. This work should be performed only by qualified stainless steel welders equiped with the proper specialized materials.

* Patches should be of the same specification as the original panel. * Patches must be watertight, fit tightly against the panel, and coated adhesive primer or bonding on the interior surface and adhere to the underlying foam. * Use caulking for final seal on rivetted overlay patches. * If the damage is too severe or extensive to be repaired by patching, the entire panel should be replaced.


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6-8.1 Riveted Overlay Patches.

If damage affect up to 300mm x 300mm on side panel, the damage can be repaired byinstalling overlap patch using of mono-bolts.( stainless steel 3/16" )

A.* Prepare the damaged panel surface so the area surruonding the damage is flat and distortion-free, and will allow the overlay patch to fit tightly to the surface.

* If wrinkles or creases cannot be flattened adequately, or the damage depth is more than 25mm, cut away with tinsmith shears, disc cutter or jig saw. Leave a rectangular hole with straight, flat, even edges.




E. Position the patch and apply even pressure to expel excess sealant. * If damaged portion is not cut-out and the depth is less than 25mm, the damaged area must be flatened( fill up) by sealant before installing patch. * the excess sealant must be removed, especially butyl must not be exposed.

F. Fasten the patch to side panel by using of stainless steel mono-bolt.




3/16" sus

rivet patching

sealing

Min.

13mm

Min.

50mm

① ②

③


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If the damage to exterior side pane exceeding 300mm x 300mm, the damage must be repaired by welding of patch or insert.

A. Mark the area to be cut out, allowing an extra margin beyond the damage. The cut- out area must be retangular or square, with straight edges. Using a disc cutter, cut away the damaged area. Grind the cut edges smooth.



patching

Foaming

inside cavity

25mm


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* The foam behind welding seam line must be removed and cleaned. D. Weld the insert or patch. * spot weld at the surrounding edges. The welds should not be longer than 50mm each time. All welds shall be made in a sequence that will balance the heat of welding during the welding process.


F. Foaming under properly securing the panels during injection and foam raising

G. When the foam is cured completely, close holes by 1/4" stainless steel mono-bolts.


PATCH

INSERT

strip

butt weldbutt weld

must be cleaned

overlap weldoverlap weld


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If steel side post is on damaged panel, straighten or renew the post, and then the postmust be welded with replacement side panel. Drill 5mm on the side panel and weldside panel to post through the holes(PLUG WELDING).

side

post

side

post

spot weld (plug weld)

in the side post.

plug

weld

plug weld

50mm

continuous

weld

continous

weldcontinous

weld


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PROCEDURE OF REPAIR.

DAMAGE CUT-OUT DAMAGED PANEL.

INSERT BACK PLATE OR POST AND TACK(SPOT) WELDING.

FULL WELDING AND FOAMING.(see foaming procedure chapter 7)

back

plate


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6-9 Side Inner Stainless Lining.

Damage to stainless steel interior lining panels can be repaired by installing riveted patches or welded inserts or patches.

* Patches should be of the same specification as the original panel. * Patches must be watertight, fit tightly against the panel, and coated adhesive primer or bonding on the interior surface and adhere to the underlying foam. * because of possible contact with foodstuffs, patch repairs must be hygienic and present a neat appearance. * Use caulking for final seal on riveted overlay patches. * If the damage is too severe or extensive to be repaired by patching, the entire panel should be replaced.

small cut.

damage affect

75% of height,

replace

side lining all height


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6-9.1 Patching Riveted Overlay.

Prepare the panel surface so the area surrounding the damage is flat and distortion-free,and will allow the overlay patch to fit tightly to the surface. If wrinkles or creases cannotbe flattened adequately, cut away with tinsmith shears, disc cutter or jig saw cutter.Leave a rectangular hole with straight, flat, even edges.

A. Cut out damaged area by disc cutter or jig saw cutter.

B. Remove damaged foam, all wet or moisture foam must be removed.

C. Prepare a patch of material of identical specification. * The patch must overlap the perimeter of the damage area by 50mm on all sides. * Cut the patch with straight edges and rounded or chamfered corner. * Foam adhesive primer must be coated to the foam side of the patch. * The patch must have same corrugation sa the original lining.

D. Apply a continuously bead of one-component polyurethane sealant between the line of the rivet holes and the edge of the patch. Be sure there are no breaks or gaps in the sealant. Alternatively use 50mm wide 1.5mm thick foam tape.

E. Position the patch and apply even pressure to expel excess sealant. If any sealant applied at the step D came out the sealant must clean, especially butyl sealant must not be exposed .

F. Clamp or clip the patch to the panel. Drill 5mm in diameter in each corner of the patch 13mm in from the edges.

G. Rivet the patch using stainless steel watertight rivets 4.7mm in diameter.

H. Apply polyurethane sealant around the patch.

I. Inject the foam into cavity. Be sure securing the patch and panel no to be bulged.

J. Clean and sealing if necessary.

Cut-out

damage area

and

remove wet

foam


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Apply sealing or

foam tape at

overlap area with

original panel.

25mm

Foam tape or sealing

between

patch and original

panel

stainless steel

mono-bolts(3/16")

Foaming

Here


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6-9.2 Replace Entire Height.

A. Cut out Top cover and Bottom flashing cover by using of disc grinder.

B. Remove fastening rivets joining with damaged side inner panel.

C. Remove damaged side inner lining and damage and/or wet foam.

D. Prepare a replacement panel of material of identical specification. * The panel must overlap the perimeter of the damage area by 50mm on all sides. * Cut the panel with straight edges . * Foam adhesive primer must be coated to the foam side of the patch. * The patch must have same corrugation as the original lining.

E. Apply a continuously bead of one-component polyurethane sealant between the line of the rivet holes and the edge of the patch. Be sure there are no breaks or gaps in the sealant. Alternatively use 50mm wide 1.5mm thick foam tape.

F. Position the replacement panel and apply even pressure to expel excess sealant. If any sealant applied at the step D,the sealant exposed must be cleaned. especially butyl sealant must not be exposed .

G. Clamp or clip the patch to the panel. Drill 5mm in diameter in each corner of the patch 13mm in from the edges.

H. Rivet the replacement panel using stainless steel watertight rivets 4.7mm in diameter.

I. Apply polyurethane sealant around the patch.

J. Inject the foam into cavity. Be sure securing the patch and panel no to bulge.

K. Clean and re-sealing if necessary.

cutting flashing cover

Remove

damaged

panel

cutting top corner cover


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Foam tape

mono-bolts

(3/16")

INJECTION FOAMING


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6-9.3 M C I T Container

Damage on Al.

side lining

Damage on Al.

scuff liner


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CUT OUT DAMAGED AREA BY DISC GRINDER.

PATCHING OR INSERTING.

patching by

blind rivets

inserting by

butt welding

prepare Al. plate

(more than 2.5mm)


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6-10 Inside Top Corner Cover.

When the damage is on the side inner lining, all cover joining with inner lining must bechecked. The damage of top corner cover can be repaired by straightening and/orsectioning.There is two kinds of different design, Two pieces of top covers are installed on theinside top corner and single piece cover is installed on the some design.Outer piece of top cover is not much affect the container in the double pieces design.The damage such as cut ,torn, broken on the inner of double pieces design and single piece design must be repaired.

* any sealing loose must be resealed by polyurethane sealant.

* any rivets missing or loose must be repaired by replacing.

A. Cut out damaged cover and remove fasteners.B. Remove damaged and old sealing, foam tape.C. Position replacement cover with foam tape and fasten by 3/16" mono-bolts.D. Apply polyurethane sealant.

BROKEN COVER

SECTION COVER

TOP CORNER

COVER

BOTTOM COVER

Butt joint & sealing

TOP CORNER

COVER

BOTTOM COVER


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6-11 Aluminum "T" Floors.

Aluminum "T" floors may be repaired by straightening or installing a complete section.The aluminum welding should be performed only by qualified welders using specialized equipment.


Minor distortion can, if required, be straightened without heat.Use s wooden wedge and mallet for straightening.

A. Place the wedge between "T" bars beyond the damaged portion of the "T" profiles. Using the mallet, drive the wedge forward through the distorted area until the profile has been restored to original shape.

B. If straightening causes cracks, weld the cracks after straightening.

6-11.2 Connection Plate at Rear End.

The damages, cut, crack, broken or missing on the connection plate at rear end must be repaired by re-welding or replacement.

Welding


Chapter 6-11



6-11.3 Section(Partial replacement of T-floors)

When the damage can not be repaired by straightening and more than two "T"-bars,the damaged "T" bars must be partially replaced with a full section.

A. Mark the damaged area to be replaced.

B. Cut the damaged "T" bars and base plate using a circular saw or thin grinding disc. The depth of the cut should be the minimum necessary to cut. * The cutting on the base plate must be midway of "T" bars. * Cut should be straight and vertical.

C. Check insulation foam. If foam needs to be repaired, remove damaged foam and inject foam from base sub-floor after completion of "T" floors repairing.

D. Grind cut edges smooth and square, and clean any contamination.

E. Prepare aluminum strips 2mm thick and 50mm wide. Place the strip between the foam and original floor on all four sides of the cut. Make 25mm of the strips to show all around.

F. Prepare a replacement "T" section from material of the same dimensions, profile, and specifications as the original floor. Allow a maximum clearance of 2mm. Apply adhesive primer to the back side of the replacement section.

Bent and

cracks

cutting the

center


Chapter 6-11



G1. If the foam surface is clean, no damaged and no need re-foaming, Apply polyurethane adhesive or polyurethane sealant to the surface of the foam, Insert the new replace section and apply weight to the replacement section in order to position the section flush with the original and good adhesion. * any glue or sealant must not be contaminated at welding seam line.

( see figure G1 )

G2. If the foam is damaged when removing damaged "T"-floor, Remove foam more than half thickness of foaming and insert the new replacement section. The repaired area must be re-foamed after welding completion.

( see figure G2 on next page )

Cut out

damaged

portion

New

replacement"T" section

Insert back plate four(4) sides all round

(2mm thick, 50mm width)

G1


Chapter 6-11



H. Tack weld "T" bars and check alignment.

I. Continuously weld into position of base plate and top of "T" bars. ( The vertical web may be cannot be welded )

J. Weld connection bars on the joining area with replacement and original section.

K. Re-foaming underneath replaced "T"-floor if foam removed.

Place

new section and weld base

plate and top

Weld

Weld

REFOAMING1/4" Alu.

Mono-bolt

G1


Chapter 6-11



weld connection plate

(3mm thcik, 50mm x 50mm)

welding connection

plate

Weld

back

plate

connection

plate


Chapter 6-11



6-11.4 Delamination of T-Floor.

In case large delamination(more than 25%) of T-floor from Insulation foam and

T-floor is moving, Floor should be fixed.

A. Mark delaminated area on base panel.

B. Cut out full width of base panel by approximately 200mm wide and remove foam up to underneath of T-floor.

C. Install base filler as sketch.

* Aluminum angel should be more than 2,0mm thickness. * Al. angle should be welded by stitch welding. * P.E filler should be connected with AL. angle and square tube by tappline screws. * Better foam inside of square tube. * Square tube must be welded with both Bottom side rail.

D. Patching base panel by welding.

E. Foaming both side of filler.

Al. angle

over 2.0mm

P.E filler

steel square tube

over 3.0mm

Tapping screw

over 5.0mm dia.

stitch welding

by 50 -200mm

patching base panel

Foaming

welding

over

50mm

remaining

foam

thickness


Chapter 6-11



F. Paint touch - up.

* Th

e fi

llers

dis

tanc

e is

from

1.5

met

er

to 2

.0 m

eter

.


Chapter 6-11



6-12 Aluminum Cross Members and T-clips.

Aluminum cross members can be repaired by any of following three methods.


Use a mechanical device such as a jack or straightening wrench.Do not apply heat. Back the jacking against a supported adjacent cross-member.

6-12.2. Stop Drilling.

Minor cracks up to 30mm within 200mm of the ends of the cross-members may berepaired by stop drilling. Use a 3mm diameter drill, drill a stop holes at each end of the crack. If any T-clips are crack, they must be replaced.

6-12.3 Replacement Cross-Member and T-clip.

When damage can not be repaired by straightening without heat, a new cross-memberor T-clip must be installed. Solid rivets or Lock-bolts should be used when replacingdamaged cross-member or T-clip.

Install T-clip into the Cross-member


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RE-INSTALL CROSS-MEMBER

WITH T-CLIP INTO THE CONTAINER

Bottom

Side

Rail

T-clipl

Cross

Member

Sub-floor

Solid rivets(9.5mm)

or

lock-bolt(9.58mm)


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6-12.4 Outrigger .

In general, Policies and procedures for steel outriggers apply equally to the repair ofCross-member and outrigger on the steel containers.(( Refer to Chapter 5-12 on repair manual for steel container ))

outrigger outrigger clip

Barrier tape

Aluminum Bottom Side Rail


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INSERTING of Partial length.

INSERTING of full length.

UNACCEPTABLE full section

of completely through profile

skip welding or

continuously

weld

continuously

weld


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6-13 Fork-lift Pocket.


Whenever possible, straighten fork-pocket side by hydraulic or mechanical means without heating, If heating is necessary to assist in straightening,the steel should beheated in only the damaged area and only up to 650° or a dull cherry-red color.

6-13.2 Inserting.

Damage to a fork-pocket side that cannot be repaired by straightening may be repairedby installing an insert. Overlapping patches must not be used on fork-pocket sidesin case of partial inserting. They present an obstruction in the pocket side that can lead to damage by fork-lift pocket tins.

The following limitations apply to fork-pocket side inserts ; * Partial insert must be flush with and butt welded to the fork-pocket side. * If the fork-pocked side of the vertical web of minimum 13mm must be left intact. * Section through the complete profile of the C-channel fork-pocket side are not permitted. If the fork-pocket side is constructed from an angle welded to a top plate, the top plate must be left intact. * The minimum length of an insert is 150mm. * If an insert would end within 150mm of another vertical weld in the fork-pocket side, the insert must be extended to the existing welds.

A. Determine the area of fork-pocket side to be replaced. If Insulation foam is damaged and need to be repaired, sub-floor should be cut and remove damaged foam.

B. Cut away the damaged portion of fork-pocket side, taking care not to damage adjacent bottom side rail, Fork-pocket straps. * On C-channel profile fork-pocket sides, a minimum of 13mm of the vertical web must be left intact.

C. Clean and smooth the cut area and the edges of the replacement plate. Bevel any edges of the insert that will be butted against the bottom side rails.

D. Patching sub-floor if necessary.

E. Fit the replacement insert, tack weld in position and check alignment. Inserts must be fitted flush allowing no more than 2mm clearance between the edges of the original part and the replacement insert.

F. Continuously weld the replacement insert to the original fork-pocket side and to the fork-pocket strap and the bottom side rail.

G. Clean and painting the repaired area.

H. Re-foaming cavity area removed during repairing and sealing.


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Sub-floor

(base panel)

Fork-pocket

Insert.

Steel bottom rail

welding

Fork-pocket

strap


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6-14 Gooseneck Tunnel.

6-14.1 Straighten.

Dents may be straightened without heating by using a jack; a flat hammer or mallet and backing plate; or by a combination of those methods. For a backing plate. Use a heavy flat object such as a dolly, etc

6-14.2 Inserting

The following limitations apply to gooseneck tunnel longitudinal rail inserts ; * Insert can be of any profile that does not extend through the entire cross sectional profile of the rail. * Insert must be fitted flush with the original rail. * The minimum length of an insert is 150mm. * If an insert would end within 150mm of another vertical rail weld such as bolster front sill,rail, the insert must be extended to that weld.

A. Determine the length and width of the rail segment to be removed. Mark where cuts are to be made. When installing an insert in the longitudinal rail, it may be necessary to cut the welds attaching the rail to the outriggers, tunnel plate, tunnel stiffeners, bolster rail and front bottom rail.

If Insulation foam is damaged and need to be repaired, sub-floor should be cut and remove damaged foam.

B. Straighten the remaining rail edges if these are bent. Clean and smooth all cut edges with a grinding disc.

C. Cut replacement insert to size from material that is equal to or of higher quality, strength and thickness than the original. If any stiffener gussets were removed from the damaged area, refit or replace these gusset in the rail profile.

D. Clean and fit replacement insert. Insert must fit flush with original rail allowing no more than 2mm clearance between adjoining surfaces.

E. Patching sub-floor if necessary.

F. Tack weld the insert in position and check alignment.

G. Continuously weld the insert to the rail. If necessary, reweld the longitudinal rail to the outriggers,tunnel plate, tunnel stiffeners, bolster rail and front bottom rail.

H. Clean, prime and top coat the repaired area according to specification.

I. Re-foaming into the patching area and sealing.


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INSERTING of Partial length.

INSERTING of full length.

Min. 150mm

skip welding or

continuously weld

continuously weld


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Bolster and T-clip

Tunnel

plate

Tunnel

outergger

and

T-clip


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6-15 Sub-Floor(Base Panel)

In general, the polices and procedures for the repairing of guide pertaining to roof panels or side panels apply equally to the repair of sub-floor(base panel).Refer to chapter 6-4.1 and 6-4.2 (Side panel patching), chapter 6-5.1 ( Sideinner lining patching) for applicable repair procedures, depending on the typeof material from which the sub-floor panel is made.

If damaged floor stringers( PVC or hard wood ) are made on the more than two(2)of partial or total loose or broken on any one, make sure that stringers are to berepaired by sectioning or replacement prior to patching or replacing a sub-floorsection.

"T" - floor

Stringer

(PVC or Wood)

Sub-floor

Cross-Member

Sub-floorStringer

(PVC or Wood)


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6-16. Corrugated Base Panel of Stainless Steel Reefer.

The damage to steel/ stainless steel base panel can be repaired by installing patches with stainless steel mono-bolts, or welding of insert or patches.

6-16.1 Patching by Mono-Bolts.

If the damage is affecting less than 1M x 1M, the damage can be repaired byinstalling an inserting or overlay patching and fastened by rivets.

A.* Prepare the damaged panel surface so the area surrounding the damage is flat and distortion-free, and will allow the overlay patch to fit tightly to the surface.

* If wrinkles or creases cannot be flattened adequately, or internal height reduced more than 30mm, cut away with tinsmith shears, disc cutter or jig saw. Leave a rectangular hole with straight, flat, even edges.

Weld patch or insert

and

Re-foaming

Install patching by

rivets.


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B. Carefully examine the foam for damage and moisture. * Remove out the damaged foam if required. * Repair "T"-floor interior of container.



E. Position the patch and apply even pressure to expel excess sealant. * If damaged portion is not cut-out, the damaged area must be flatened(fill up) by sealant before installing patch.

F. Fasten the patch to roof panel by using of stainless steel mono-bolt. * the distance is 25mm pitch.




RefoamPatch

3/16" stainless steel mono-bolts

25mm


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If the damage to exterior side pane exceeding 1M x 1M, the damage must be repaired by welding of patch or insert.

A. Mark the area to be cut out, allowing an extra margin beyond the damage. The cut- out area must be retangular or square, with straight edges. Using a disc cutter, cut away the damaged area. Grind the cut edges smooth.

B. Carefully examine the foam for damage and moisture. * Remove out the damaged foam if required. * Repair(straitening) "T"-floor interior of container.




* The foam behind welding seam line must be removed and cleaned. D. Weld the insert or patch.


F. Foaming under properly securing the panels during injection and foam swalling.

G. When the foam is cured compltely, close holes by 1/4" stainless steel mono-bolts.



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Weld patch,

more than 1m x 1m.

Foam patched area.

must be cleaned

before weldingcontinuous

weldcontinuous

weld


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6-16.3 FLAT BASE PANEL. (MCIT, DENMARK CONTAINER)

The repair method of flat base panel is following Aluminum Sub-Floor.The damage less tan 1M x 1M can be repaired by overlay patching by blind rivets andinserting or overlay patching by welding in more than 1M x 1M size.

Tunnel B

ols

ter

Goose

neck

Tunnel

Load

Mem

ber

Bottom

Sid

e R

ail

If loan-member is bowing

down or bent more than 15mm,

the load-member must be

repaired, straightening or

section, inserting.

welding

riveting


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6-17 Front Corner post.

Damage to corner posts of refrigerated containers can be repaired by straightening,inserting or complete replacement, depending on the extent of damage.Sections are not allowed in corner post. Whenever possible, damaged shouldbe corrected by straightening without heating. Damage that cannot be repaired bystraightening may be repaired by installing an insert. If damage is too severe, the entire corner post must be replaced.

* Damage to posts which results in accompanying damaged to other reefer parts may have to be repaired not to damage reefer Machine parts.


Whenever possible, straighten any dents or distortions in corner post by mechanicalor hydraulic means without heating. If the dents cannot be straightened without heating, heat may be applied to assist in straightening the damaged area. When heat is used,the steel should be heated only in the damaged area and must be heated beyond a dull cherry-red color approximately 650℃.

6-17.2 Inserting.

Damage that cannot be repaired by straightening may be repaired by replacing the damaged area with an insert. Sections through the complete cross-sectional profile of the post are not permitted.

* Insert must be a minimum 150mm in length. There is no maximum length limitations for inserts. Full height corner post inserts are acceptable.* A maximum of two(2) inserts are allowed in a corner post.* Insert may be rectangular, oval, diamond in shape.* If an insert would end within 300mm of a corner fitting, It must be extended to the corner fitting.* Inserts must not terminate vertivally on a formed edge.* Inserts must be fitted flush with the original material and butt welded.* An insert in a square-profile corner post may extend through only one formed edge.* An insert may not terminate horizontally within 13mm of any formed edge. In addition, the insert must extended through at least 75mm of the cross-sectional profile of the corner posts.* When a corner post contains two(2) inserts, no part of either insert may occipy any part of the same horizontal plane.* Horizontal inserts welds of rectangular or diamond, oval shapes inserts must be a minimum 150mm a part.* An insert that would terminate within 150mm of an existing insert must be extended to that insert to form a common weld. NOTE ; The common weld must extend horizontally through the profile of the post. When diamond or oval shape inserts are involved, they must, therefore, be cut to provide a horizontal edge that will butt against and be welded to the adjacent insert.


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A. Determine the length, height and profile of the area to be replace and mark around its perimeter.

* Damage to posts which results in accompanying damaged to other reefer parts, the reefer machine must be removed before cutting the damage.

B. Position guide bar to ensure straight cut with an oxygen acetylene torch. this procedure will avoid creating excessive gaps, created by irregular cuts, between the replacement insert and the remaining portion of the corner post.

* If the damage is on the post or flange which is insulation foam directly, the damage must be cut by disc cutter not to burn the foaming.

FRONT INNER

CORNER POST

FRONT OUTER

CORNER POST


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C. Cut out damaged area of the post. Clean and smooth all frame-cut areas with a grinding disc. Remove damaged insulating foam, which is existing behind of post to be welded.

D. Cut a replacement insert. It should be made from material that is equal to or of higher quality, strength and thickness than the original post. The dadius of the formed edge of the insert must be identical to the dadius of the original post so that the surface of the insert and corner post can be properly aligned.

E. In order to ensure full weld penetration, bevel adjoining surface to a 30° angle, original and insert post materials.

F. Fit the replacement insert flush with the original post, tack weld, check alignment, if accessible, continuously weld by full penetration.

G. Clean welding slags and any bunt paint, welding spatters.

H. Apply zinc primer by brush and top coat according to specification.

I. Patching side panel if the damage was post flange joining with side panel.

J. Re-foaming if the removed when inserting works.

K. Re-install reefer machine if the machine was removed.

INSERTING

FRONT CORNER POST


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FIGURE OF INSERTING OF FRONT CORNER POST.

AC

CEPTABLE C

ASE O

F IN

SER

TIN

G.Min

.

300m

m

Min

.

150m

m

Min

.

150m

mM

in.

150m

m

Min

.

300m

m

Min

.

300m

m

Min

.

300m

m

com

mon

weld

seam

full

heig

ht.


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FIGURE OF INSERTING OF FRONT CORNER POST.

NO

T A

CC

EPTAB

LE C

ASE O

F IN

SER

TIN

G.

less than

300m

m

inserted

thro

ugh

the s

ection

iinserted m

ore

than tw

o p

ieces.

two insert o

ccupie

d

at th

e s

am

e

horizo

nta

l pla

ne.

tless than

150m

m

inserted

thro

ugh

the s

ection


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6-17.3 Replacement entire Corner Post.

When damage to a corner post can not be repaired by straightening or insert,the entire corner post must be replaced.The replacement post material is the same or greater in strength(yield point andtensile strength) than the original post.

A. Remove reefer machine and inside plates, air guide plate on the side and roof.

B. Remove inside cover plates joining with side and roof inner lining and damaged side panel.

C. Remove insulating foam from damaged post.

D. Using an oxygen acetylene torch, cut out the damaged post.

E. When all edges are cut free, remove the post. Use a grinding disc to clean and smooth the cut edges.

F. Prepare replacement corner post. May be inner and outer post.

① Remove

reefer ② Remove air

guide panels

③ Remove

PVC④ Remove

inner

⑤ Remove

foam

⑥Remove damaged corner post


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G. Bevel the egdes of the new corner post that are to be welded to the corner casting to a 45° angle, in order to allow complete weld penetration. The joint gap must be no more than 2mm before welding.

H. Fit replacement post into position, Tack weld and check alignment, dimension.

I. Continuously weld new post to corner casting by uniform, free of scale, pin and blow holes, and with full penetration. All welds to corner casting should be made with low-hydrogen welding rods or wire in order to minimize any changes of hydrogen embrittlement in the weld. To ensure proper engagement of container handling devices, it is important that the distance between aperture centers be maintained within the tolerances. Care must also be taken assure that the fitting height, measured between the top and bottom corner casting, is within ISO dimensional tolerances and that the corner casting is properly positioned horizontally.

J. Check alignment by measuring the height, width, length and diagonal dimension of the container. All dimension must conform to ISO specifications.

K. Install reefer machine into the front and mark the holes of mounting bolts of reefer machine and remove machine again.

L. Drill holes and install nuts of mounting bolts of reefer machine.

M. Clean welding slags and any burn paint, welding spatters.

N. Apply zinc primer by brush or roller and top coat.

O. Patching or replacing side panel involving repairs.

P. Re-foaming under securing panels, inside and out side.

Q. Clean and sealing after completely foam curing and install inside air guides plate.

R. Re-install reefer machine and apply sealant all around machine.


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REPLACEMENT ENTIRE FRONT CORNER POST OF STAINLESS STEEL REEFER.

① Install new

PVC connector ② Re-install

inner cover

④ Re-install air

guide panels.

③ Re-foaming

⑤ Re-install

reefer machine


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POST OUTER

POST INNER


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6-18 Front Header.

The damage, cuts, torns to front header up to depth 25mm can be repaired by welding of the patching plates.The front face of the header must be flatted and reefer machine must be mountedproperly. If any gap between header and machine, and can not be repaired by tightening of the mount bolts, remove machine and flatten the surface by straighteningor inserting, then re-install machine.

6-18.1 Welding of Patch of Front Header.

* Check the surface joining with reefer machine.

If no damage front face and machine is installed properly.

A. Make a flat the damaged area by sealing or similar. If aluminum roof panel is damaged, the damaged aluminum panel must be removed.

B. Weld patching onto the damaged header and painting according to specification.

Fill up the

sealing into

weld patching

Front header

Clip on device


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6-18.2 Inserting of Front Header.

If front face is damaged and gap between machine and header. The damage must berepaired by inserting and install mounting nuts on position.

If the damages, cuts, torn depth is more than 25mm, damaged portion must be cut away and installed inserting plate.

TOP SURFACE ( no damaged at joining face with machine.)

A. Cut away damaged portion by disc cutter. Do not use flame torch.

B. Remove damaged foam, wet or broken.

C. Place the inserting plate and tack weld.

D. Continuously weld and remove burn paint and welding slags. ( the insert plate must be coated by primer )

E. Apply zinc primer by brush and top coating.

F. Re-foam the repaired area through holes by 6.5mm and plug the injection and air release hole by 6.4mm(1/4") diameter mono-bolts.

FRONT FACE. (damaged joining face with machine)

A. Remove reefer machine and remove old seal tape and sealing.

B. Cut away damaged portion by disc cutter. May be the PVC connector also need to be repaired, section of PVC connector is allowed if necessary.

C. Place the inserting plate or angle plate on position and tack weld.

D. Measure the nut position of mounting and install mounting nuts.

Re-foam

Inserting


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E. Continuously weld the inserting plate and remove burn paint and slag,etc. ( the insert plate must be coated by primer )

F. Apply zinc primer by brush and top coating on the exterior.

G. Re-foam the repaired area through holes by 6.5mm or mounting nuts and plug holes and air release hole by 6.4mm(1/4") diameter mono-bolts.

H. Re-install reefer machine with new seal tape in the overlap surface with front frame.

I. Apply urethane sealant all round machine.


Any damage to top wing plates, broken or distortion must be repaired by straighteningor inserting, replacement.

Re-foam

Inserting

Inserting Wing Plate Replace Wing Plate


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6-18.4 Clip on Device Angle.

The damage to Clip on Device Angle, bent, distortion must be repaired by straighteningor replacement. Section and inserting are not allowed.

6-18.5 Replacement of Entire front header.

When damage to a front header can not be repaired by straightening or insert,the entire header plate must be replaced.The replacement material is the same or greater in strength(yield point andtensile strength) than the original post.

A. Remove reefer machine.

B. Remove inside air guide plates, top and sides, bottom.

C. Remove inner lining cover at top side.

D. Remove foam insulated with front header.

E. Remove all fasteners jointing with roof panel.

F. Cut out welding joint with top wing plates and corner casting.

G. Pull out damaged front header.

H. Install new front header. The replacement header must be coated painting according to specification and foam adhesive primer on the interior.

I. Weld and rivet with roof panel. Reinstall inside cover.

12mm

56mm

Ø 60mm


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J. Painting welded area and foaming under securing cavity area not to bulged.

K. Clean and apply sealant same as the original.

L. Re-install reefer machine with new seal tape at overlap area with front frame.

M. Apply polyurethane sealant all round machine.

①Remove machine

③Remove top

side cover

②Remove PVC

connector④Remove top

lining cover

⑥Remove

damagedheader plate

Clip on

device and

gusset plate

⑤Remove foam


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1118mm


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REPLACEMENT FRONT HEADER OF STAINLESS STEEL REEFER.

①Replace Top Header

with clip on device and gusset plates.

②Reinstall PVC

connectorand lining cover

③Re-foaming

④Re-install

Machine


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FRONT HEADER

GUSSET(CORNET PROTECTOR)

CLIP ON DEVICE


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6-19 Front Sill(Bottom Rail)

The damage, cuts, torns to front sill can be repaired by straightening or welding aninsert after remove inner cover and damaged foam. If the damage is too severe and more economical, replace entire sill section.The front face of the sill must be flattened and reefer machine must be mountedproperly. If any gap between sill and machine, and can not be repaired by tightening of the mounting bolts, remove machine and flatten the surface by straightening or inserting, then re-install machine.

6-19.1 Inserting of Front Sill.

BOTTOM SURFACE ( no damaged at joining face with machine.)





E. Apply zinc primer by brush and top coating.


** If damage is under base part only, It can be repaired by welding of patching.

Front Sill inner

Front Sill outer

Gooseneck


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TOP FACE. (damaged joining face with machine)

A. Remove reefer machine and remove old seal tape and sealing.

B. Cut away damaged portion by disc cutter. May be the PVC connector also need to be repaired, section of PVC connector is allowed if necessary.

C. Place the inserting plate or angle plate on position and tack weld. * The insert plate must be fitted by flush and butt welding.

D. Measure the nut position of mounting and install mounting nuts.

E. Continuously weld the inserting plate and remove burn paint and slags,etc. ( the insert plate must be coated by primer )

F. Apply zinc primer by brush and top coating on the exterior.

G. Re-foam the repaired area through holes by 6.5mm or mounting nuts and plug holes and air release hole by 6.4mm(1/4") diameter mono-bolts.

H. Re-install reefer machine with new seal tape in the overlap surface with front frame.

I. Apply urethane sealant all round machine.

6-19.2 Replacement of Entire front sill.

When damage to a Front Sill can not be repaired by straightening or insert,the entire Front Sill must be replaced.The replacement material is the same or greater in strength(yield point andtensile strength) than the original post.

A. Remove reefer machine.

B. Remove inside air guide plates, bottom and sides.

C. Remove inner lining cover, bottom and sides.

D. Remove foam insulated with front sill.

E. Remove all fasteners jointing with front frame to sub-floor, both side.

F. Cut out welding joining with gooseneck tunnel plate.

G. Pull out damaged front sill.

H. Install new front sill. The replacement sill must be coated painting according to specification and foam adhesive primer on the interior.

I. weld and rivet with original parts and check dimension.


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J. Painting welded area and foaming under securing cavity area not to bulged.


L. Re-install reefer machine with new seal tape at overlap area with front frame.

M. Apply polyurethane sealant all round machine.

①Remove

Machine

②Remove

kick plate

③Remove

PVC

④Remove

lining cover

⑤Remove

foam

⑥Take away

damaged Sill

①

②③

④ ⑤

⑥

REINSTALL

ALL PARTS


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6-19.3 Front Bottom Wing Plate.

Any damage to bottom wing plates, broken or distortion must be repaired by straightening or replacement.

Connection

angle

Bottom Wing

Plate

Bottom Side

Rail


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REPLACEMENT FRONT SILL OF STAINLESS STEEL REEFER.

FRONT SILL OUTER

FRONT SILL INNER

CORNER PROTECTOR


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6-20 Rear Corner post.

Damage to corner posts of refrigerated containers can be repaired by straightening,inserting or complete replacement, depending on the extent of damage.Sections are not allowed in corner post. Whenever possible, damaged shouldbe corrected by straightening without heating. Damage that cannot be repaired bystraightening may be repaired by installing an insert. If damage is too severe to berepaired by inserting, the entire corner post must be replaced.


Whenever possible, straighten any dents or distortions in corner post by mechanicalor hydraulic means without heating. If the dents cannot be straightened without heating, heat may be applied to assist in straightening the damaged area. When heat is used,the steel should be heated only in the damaged area and must be heated beyond a dull cherry-red color approximately 650℃.

6-20.2 Inserting of Rear corner post.(J-Bar)

Damage that cannot be repaired by straightening may be repaired by replacing the damaged area with an insert. Sections through the complete cross-sectional profile of the post are not permitted.

* Insert must be a minimum 75mm in length. * Inserts must not terminate vertically on a formed edge.* Inserts must be fitted flush with the original material and butt welded.

A. Determine the length, height and profile of the area to be replace and mark around its perimeter. Remove all rivets from adjoining panels. Cut out damaged area of J-Bar. * Carefully shield any area of foam which might be damaged in the repair procedure. Clean and smooth all cut areas with a grinding disc.

B. Cut a replacement insert from the same material as the original.

C. Check adjoining foam condition, If necessary, remove damaged foam.

D. Fit the insert flush with the original post. Tack weld in position and check alignment.

E. Continuously weld the insert to the post along both side of joint.

F. Clean and apply primer and top coat.

G. Patching side panel or/and inner panel if removed.

H. Re-foaming, if necessary. And sealing repaired area.


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6-20.3 Replacement of entire Rear Post.

When damage to a corner post can not be repaired by straightening or insert,the entire corner post must be replaced.The replacement post material is the same or greater in strength(yield point andtensile strength) than the original post.

A. Remove all rivets from adjacent panels. If necessary, side panels away from post with wedges. Remove any sections of damaged foam,as well as any foam that will be damaged by the repair process.

B. Remove inner lining covers and door .

C. Cut out damaged corner post. * Outer post must be cut full height and inner post must be left 150mm from the top face of bottom corner casting.

150mm

post

outerpost

inner

leave inner post

about 150mm

Bevel

Replacement

post,

inner and outer


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D. Remove the post and clean all cut edges with a grinding disc.

E. Bevel 45˚ the edges of replacement post and remaining inner post at bottom to be welded to the corner casting to allow complete weld penetration.

F. Check the foam to adjacent, If foam is burn, all burn foam must be removed.

G. Fit the replacement post into position, tack weld and check alignment. * Reinforcement bar must be welded onto the outre post or inner post.

H. Continuously weld the new post to the corner casting and remaining inner post by full welding penetration. Ensure that ISO dimensions and tolerances are maintained.

I. Clean all welding slags,burn paint and foam.

J. Apply zinc primer by brush and top coat according to specification.

K. Re-install adjacent parts, side panel with foam tape, inner covers, top covers.

L. Re-foam repaired area under proper securing panels and covers.

M. Apply polyurethane sealant and door installation.

inner

covers

T-floor

Replaced

post

Re-

foamed


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REPLACEMENT ENTIRE REAR CORNER POST OF STAINLESS STEEL REEFER.

POST INNER

①&②

REINFORCEMENT

PLATE

POST OUTER

PVC

COVER

LINING

COVER

POST OUTER

POST INNER

①&②

DOOR HINGE LUG

reinforcement

plate


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6-21 Rear Header.

6-21.1 patching of Rear Header.

The damage, cuts, torns to front header up to depth 25mm can be repaired by installing of the patching plates except cam-keeper and door gasket contact area.

6-21.2 Inserting of Rear Header.

If the damages depth of cuts, torn is more than 25mm, damaged portion must be cut away and installed inserting plate and refoam.





E. Apply zinc primer by brush along welding seam, insert and top coating.


fill up the cavity

by sealingcan be repaired by

patching

Insert

foaming

replace

Insert


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6-21.3 Replacement of Entire Rear Header.

When damage to a rear header can not be repaired by straightening or insert,the entire header plate must be replaced.The replacement material is the same or greater in strength(yield point andtensile strength) than the original post.(SEE PAGE 4 FOR HERDER STRUCTURE)

A. Remove door assembly.

B. Remove inside inner top lining cover and PVC.

C. Remove foam insulated with header.

D. Remove all fasteners jointing with rear header and roof panel.

E. Cut out welding joint with top wing plates and corner casting, corner post.

F. Pull out damaged rear header.

G. Install new header plate. The replacement header must be coated painting according to specification and foam adhesive primer on the interior.

Rear Header

outer

Rear Header

inner

Top Wing Plate


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H. Weld and rivet with roof panel and check dimension.

I. Reinstall inner lining cover and new PVC connector.

J. Painting welded area and foaming under securing cavity area not to be bulged.


L. Re-install doors and check door operation.


Any damage to top wing plates, broken or distortion must be repaired by straighteningor inserting, replacement.

Rear Header

outer

Roof Panel

Lining

Cover

Rear

Header

Cam Keeper

FOAMING

PVC

Cover


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REPLACEMENT ENTIRE REAR HEADER OF STAINLESS STEEL REEFER.

HEADER INNER

HEADER OUTER

GUSSET

(CORNER PROTECTOR)

PVC COVERLINING COVER

CAM-KEEPER

HEADER INNER

HEADER OUTER

CAM-KEEPER


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6-21.5 Replacement of CamKeeper.

If camkeeper has damaged and doors can not be operated properly, the keeper must be straightened or replaced.

A. Check door operation, close and open.

B. If cam and keeper are not combinated properly, straighten Cam-keeper.

C. If the damage can not be repaired by straightening, replace the damaged Cam-keeper.

D. Open the doors and remove the damaged keeper by disc grinder.

E. Clean the surface which will be attached new keeper.

F. Close the door with new keeper to set the position of the keeper's weld. G. Tack weld and open and close the door to check operating of the doors.

H. Continuously weld the replacement keeper.

I. Clean and smooth the welded surface.

J. Apply primer by brush and top coat according to specification.

Broken keeper with header

plate.

Insert header plate and

replace keeper.


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6-22 Rear Sill.(Door Sill)

6-22.1 patching of Rear Sill.

Damage on base part of the rear sill can be repaired by welding of patch.

6-22.2 Inserting of Rear Sill.

If the damage can not be repaired by straighten and Re-weld, The damage can berepaired by installing insert plate.

A. Mark and cut out the damaged area with a cutting disc.

B. Remove damaged foam if required.

C. Cut the replacement material to size.

* Insert should be fabricated to allow no more than 2mm clearance between adjoining surface. Insert plate material must mate with the bending profile and radius of the original panel. * If a section would end within 150mm of another rail weld, It must be extend to that welding.

Rear sill

(base part)

Rear sill

(outer part)

Patching &

re-foam

Butt weld of Insert plate.

(re-foam & replace keeper, if necessary)


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D. Grind the cut edges of the existing and replacement Sill smooth and clean.

E. Fit the insert and tack weld in position.

F. Continuously weld to the exterior of the insert plate. G. Clean all welding slag, burn paint and remove weld spatters.

H. Mask and primer the exterior of the repair area by using brush.

I. Spray top coat and dry the paint. And Re foaming if necessary.

6-22.3 Replacement of Entire Rear Sill.

When damage to a rear sill can not be repaired by straightening or insert,the entire sill plate must be replaced.The replacement material is the same or greater in strength(yield point andtensile strength) than the original post.

Rear Sill -

BASE PART.

Rear Sill -

OUTER PART.

Cutting Here


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A. Cut welding joint with corner casting, corner post and base sill plate.(inner)

B. Remove damaged rear sill(outer)

C. Remove foam insulated with rear sill.

D. Install new rear sill. The replacement sill must be coated painting according to specification and foam adhesive primer on the interior.

E. Tack weld and check alignment, then continuously weld to the original sill, casting, corner post. Clean the welding slags, etc.

F. Painting welded area, and foaming under securing cavity area not to bulged.

G. Clean and apply sealant same as the original.

Cutting Here

four(4) gussets

Replaced

Rear Sill Outer

Re-foam


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6-22.4 Rear Bottom Wing Plate.

Any damage to bottom wing plates, broken or distortion must be repaired by straightening or replacement.

6-22.5 Replacement of CamKeeper.

If camkeeper has damaged and doors can not be operated properly, The keeper must be straightened or replaced.

A. Check door operation, close and open.

B. If cam and keeper are not combinated properly, straighten Cam-keeper.

C. If the damage can not be repaired by straightening, replace the damaged Cam-keeper.

D. Open the doors and remove the damaged keeper by disc grinder.

E. Clean the surface which will be attached new keeper.

F. Close the door with new keeper to set the position of the keeper's weld.

G. Tack weld and open and close the door to check operating of the doors.

H. Continuously weld the replacement keeper.

I. Clean and smooth the welded surface.

J. Apply primer by brush and top coat according to specification.

Wing plate

connection

angle


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6-23 Door Assembly.

Damage to doors can be repaired by installing patched on the lining or out side panel,replacing the inner lining, replacing the entire door. If damages involves the plywood core of a plymetal door, a plywood plug of the same core thickness and materialmust be inserted into the door prior to installing a patch in the panel.

6-23.1 Patching of Door lining and panel.

refer to patching procedure on Aluminum side panel and/or inner side lining.

Plywood

core-plymetal

door

Stainless steel door lining

PVC frame

outer

gasket

inner(thermal)

gasket

Insulation

foam

Patching

inner lining

Plymetal door type


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6-23.2 PVC Frame damage.

Damage to PVC frame usually happen with inner lining or Al. frame together.The damage can be repaired by installing section piece and straighten Al. frameand patching inner lining.

A. Cut inner lining bt disc grinder if damaged.

B. Pull out inner door gasket and cut out damaged PVC frame, must be straight, by disc cutter or grinder, and remove damaged foam.

C. Straighten Al. frame if damaged.

D. Prepare PVC section to size. The section piece must be made from same shape as original.

E. Place the section on position and grind projecting part of PVC frame.

F. Drill 4.8mm and rivets by 4.7mm mono-bolts with Al. frame together and install reinforcement aluminum plate(3mm thick) on lining side then fasten mono-bolts.

G. Foaming and clean, sealing.

Section of

PVC frame

Fasten

mono-bolts

(3/16')

13mm

25mm

reinforce

Al. plate

Al. frame

(original)

remove

inner gasket

damage here


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6-23.3 Door hard-ware.


Whenever possible, straighten all of door hard-ware, locking rod,handle, handle catches, hinges,brackets,without heating, Do not use heat if locking bar guides or brackets having plastic bushings. Shield the door panel when heating locking rods. After straightening the locking rod, clean, prime and top coat area of damaged coating.

6-23.3.2 Section the Locking Rod.

The locking rod extends from top to bottom locking cams. Anti-racking rings are normallywelded to either end of the rod where it enters the bearing brackets. * Section repair to locking rod must be a minimum length of 150mm. * Sections are not permitted within 150mm of another full profile weld in locking rod.

A. Mark where the locking rod is to be cut. If the damage extends to an anti-rack ring, the rod should be cut 13mm from the anti-racking ring.

B. Cut through the locking rod and remove the damaged section. If a cutting torch is used shield the door panel to prevent damage painting by burning. * If the damaged section of locking rod extends through or ends near a guids(bracket), the guides must be removed before removing damaged rod. * If the damaged section of bar is attached to door handle, remove the handle from damaged locking rod by cutting the welding joining door handle hub to locking rod. * If the entire section of rod between the bearing brackets require replacement, all guids must be removed before removing damaged rod.

C. Clean and smooth the cut areas and the cut ends of the remaining rod. * Bevel the edges of the rod for good weld penetration.

D. Position the replacement section and tack weld, check alignment. ( It is important that the vertical alignment of the locking rod be properly restored and that the locking rod cams are fully engaged when doors are closed and locked)

E. Open the door, continuously weld one side of both end of the rod and turn the locking rod 180° and continuously weld the other side to obtain a 360° weld seam.

F. Reattach the door handle to the locking rod by welding of the handle hub to the rod, and another brackets, bearing. If removed before cutting out of damaged section.

G. Clean, primer, top coat the repaired area.(must be applied zinc primer by brush)


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SECTION

LOCKING BAR

Lock-Bar

Large bracket

Large

Small

Small

Handle

Handle

Handle Hub

Cam

Anti-racking

ring

Large

Large bracket


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6-23.3.3 Replacement entire locking rod.

A. Remove all fasteners, When loosing door bolt, do not use air tool, It may be loosed inside nuts, the bolts must be loosed by the hands and slowly, carefully. * In case of TIR bolts, weld steel bar to head of TIR bolt and loose carefully by hands. ( see sketch on previous page )

B. Remove all attching parts, bearings, brackets.

C. position replacement locking rod and check dimension. * the dimension of the replacement locking rod must be same as the original.

D. Install replacement locking rod by bolts removed and check door operation.

Locking Bar Bolt

Nut

Tack weld

Tack weld

W

steel bar

TIR bolt


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6-23.3.4 Hinge pin.

Free hinge pins by lubricating the hinge with penetrating oil.Never use heat to free hinges fitted plastic bushing.Remove any welding attaching the hinge pin to hinge lugs. Apply penetrating oil and drive the pin out of hinge lug with a hammer and punch.

6-23.3.5 Hinge blade.

If the damage is on the hinge blade and can not be repaired by straightening, it must be replaced.

* Remove the bolts. * Remove the damaged hinge blade. * Fit the replacement hinge blade on position and fasten the bolts.

Be carefull when loosing and tightening all bolts, the tack weld of inside between nuts and plate is weak. Air tool, therefore, is not recommended to use.

6-23.3.6 Bearing Brackets ( inner & outer ), door handle, etc

Whenever possible, straighten the damaged parts of door hard-ware including brackets, small and large, and door handle. If the damage can not be repaired by straightening,the damaged parts must be replaced.

plymetal door

binge blade

bolts


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6-23.4 Door Gaskets.

6-23.4.1 Bonding.

Door gaskets that are cut may be repaired by bonding together the cut edges of the gasket providing that no gasket material is missing and the cut edges mate together.

A. Roughen the cut edges of the gasket and wipe clean with acetone.

B. Apply a very thin film with the adhesive to one cut edge of the gasket and immediately mate to the other cut edge spreading the adhesive by slightly rubbing the two surface together.C. Apply light pressure for a few seconds until the bond cures sufficiently to hold the cut gasket edges together.

** The bond or adhesive must be kept flexible properties after curing. the brittle bonding or sealants can not be used.

6-23.4.2 Sectioning.

Damage to the door gasket that can not be repaired by bonding may be repaired byinstalling a section. A door gasket section extends through the complete cross sectional profile of the inner or outer gasket.

thin film with

adhesive


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OUTER GASKET(PLYMETAL DOOR)

A. Cut-out damaged portion by sharp knife and scraper. (Outer gasket have adhesived with plymetal door) B. Attach new section outer gasket to plymetal door by using of glue.

C. Roughen the cut edges of the remaining gasket and section and wipe clean with acetone.

F. Apply a very thin film with the adhesive to one cut edge of the gasket and immediately mate

to the other cut edge spreading the adhesive by slightly rubbing the two surface together.

G. Apply light pressure for a few seconds until the bond cures sufficiently to hold the cut gasket edges together.

thin film with

adhesive

section


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INNER GASKET.( TWO LIP TYPE)

A. Pull out inner gasket and cut damaged portion.

B. Clean PVC frame which will be inserted inner gasket by slovent or acetone.

C. Apply urethane sealant on the PVC frame as adhesive.

D. Place sectional new inner gasket into original position.

E. Fasten the gasket at end of replacement and original gasket by using of 4.7mm mono-bolt. (length must enough long)

apply sealant prior to

install section gasket.

install 3/16"

mono-bolts


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6-23.5 Out-panel delamination.

The damage delaminated out-door panel from insulationof the door must be fixed again.

A. Remove gasket from edge of delaminated and clean inbetween out-panel and foam.

B. Insert glue or polyurethane sealant as mush as possible (push to inside by the plate)

C. Brace door delaminated area.

door

outer panel

delaminated

clean

the surface

delaminated

thin plate

press together

using "C" clampWood

supporter


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D. Drill through inner lining to out-panel by 10mm diameter.

E. Apply sealing into the holes and on the reinforcement plate. ( use reinforcement plate : morethan 5mm thick 50mm width. Aluminum or Stainless steel)

F. Tighten 10mm dia. Through inside to outside. (Head inside, nut -outside)

G. Remove excess sealant to fix the gasket.

H. Fix the door gasket with sealant underneath.

I. Keep open the door until sealant dry completely.

polyurethane

sealant

50mm

= = =

25mm

bolts and nuts

M10 x 120LG,

stainless steel,round head.

sealing


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6-23.6 DOOR DESIGN TYPES.

6-23.6.1 Plymetal out door design.

TOP

BOTTOM

Outer gasket

Al. frame

PVC frame Inner gasket

Nut and

bracket.

Door

lining

Plymetal

door

LEFT

RIG

HT

Plymetal

door

Door

lining

Nut and

bracket.

Outer gasket

Al. frame

Inner gasket

PVC frame


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6-23.6.2 Fabricated Door 1.

TOP

BOTTOM

PVC frame Inner gasket

Outer gasket

Al. frame

Door outer

panel

(Stainless

steel plate)

Door

lining

Gasket

retainer

Horizontal

member

Verticall

member

LEFT

CEN

TR

E

Inner gasket

PVC frame

Al. frame

Door outer

panel

(Stainless

steel plate)

Door

lining

Vertical

member


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6-23.6.3 Fabricated Door 2. (MCI Qingdao)

TOP

BOTTOM

PVC frame

Inner gasket

Door outer

panel(Stainless

steel plate)

Door

lining

Outer gasket

Gasket

retainer

Horizontal

member

LEFT

CEN

TR

E

Inner gasket

PVC frame

Vertical

member

PVC frame

Inner gasket


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6-23.6.4 Fabricated Door 3. (MCIT,Denmark)

outer panel

inner lining

door frame

TOP

BOTTOM

RIG

HT

CEN

TR

E


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7. INSULATION FOAM.


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7-0 Genral Repair Policy for Foam Insulation

Insulating foam prevents the migration of heat from the ambient air outside thecontainer to the cargo inside the container. Foam also provides a degree of stiffness,damage resistance and structural support, which varies according to container design.When cured, foam is a rigid plastic containing small, uniform closed cells filled with refrigerant gas. The combination of the gas and the gives foam its insulating qualities.

The strength of the foam depends on its density: the more dense the foam, the stronger it is. The proper foam density in replacement material is important to maintain structural integrity in the container.

7-1 Types of Foam Insulation.

Two- component polyurethane foams are the most common material for container repair. Polyurethane is a plastic that is formed when two chemicals, isocyanates,(component A) and polyols(component B), are combind. When the chemical reaction resulting from mixing the two components takes place in the presence of a blowing agent, a solid celluar foam structure of foam.

7-2. Calculation of required chemicals.

When refoaming, the chemicals must be mixed in the correct ratio and temperate.This is always 1:1

Using injection foaming machine this should cause no problem, as the machine is constructed to handle this matter.

For manual refoaming, you must take ensure that the ratio is correct.Therefore always use an even-sided bottle for the mixing of the chemicals, andalways mark the sides of the bottles, how much of each chemical you have to fill in.

Mixing of the two foam components is important. If the components are not mixedproperly, the refoaming will fail. The foam will not expand correctly, and thestrength and the insulation ability will be lost.

For both the injection foaming machine, and for manual refoaming, you must calculate the correct amount of foam to be used.If you fill too little foam you will make a free-surface refoaming. The density of the foam in the free-surface refoaming will be too low, and the strength will be insufficient.

The foam components and the parts to be reformed must have the correct temperature.If the temperature is too low, the foam will not expand correctly, the foam will get veryhigh densit, and the heat insulating ability will be poor.If the components are too warm, the foam will expand too much, and the strength will be lost.


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The ideal temperature for the foam components is 20 deg. C (68 deg. F).The container parts to be refoamed should have a temperature in the range of 20 deg. C to 40 deg. C (68 deg. F to 104 deg. F)

7-2.1 Injection Foaming Machine.

A. Calculate the volume of the cavity to be refoamed.

V = Volume of cavity (㎥)I = Length of cavity (m)B = Width of cavity (m)D = Depth of cavity (m)

B. Calculate the required amount of chemical to be used.

Q = Quantity of foam (kg)V = Volume of cavity (㎥)D = Density of foam (kg / ㎥) ( required 65kg/㎥)

C. Calculate the time(in second) the injection foaming machine shall be activated to give the required amount of foam.

t = Injection Time (sec)Q = Quantity of foam (kg)C = Capacity of Foaming Machine (Liter/sec)

7-2.2 Manual Re-foaming

A. Calculate the volume of the cavity to be refoamed.

V = Volume of cavity (㎥)I = Length of cavity (m)B = Width of cavity (m)D = Depth of cavity (m)

V = I x B x D

Q = V x D

t = Q / (C x 100)

V = I x B x D


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B. Calculate the required amount of chemical to be used.

Q = Quantity of foam (kg)V = Volume of cavity (㎥)D = Density of foam (kg / ㎥) ( required 65kg/㎥)

C. Add 30% to cover the waste of chemicals retained in the bottles, funnel, air escape holes, etc.

D. Divide quantity by two(2) to get the amount of EACH chemical.

Qa = Amount of component AQb = Amount of component B

7-3 Preparation of container for Re-foaming.

A. Section of bottom side rail.

Q = V x D

Qr = Q x 1.3

Qa = Qr / 2

Qb = Qr / 2

Inject foam

air escape

& Inject foamair escape

& Inject foam

air escape

& Inject foam


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B. Section of top side rail.

C. Roof panel, section, patching, replacing full width.

Inject foam

air escape

& Inject foam

patching and

re-foaming

replace full width

and re-foaming


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D. Side panel, patching, replacing full height.

replaced portion

replaced area

①

②

③

④

⑤

⑥

FOAM HEREinside

out side


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FOAM HERE


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E. End frame, corner post, header.

replaced header

FOAM HERE

①② ③ ④

replaced

Rear Corner Post

FOAM HERE

①

②

③

④


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7-4 RE-FOAMING

In order to ensure that the strength and insulation capability of the reefer box will notbe reduced by the repair it is important to follow the instructionsmentioned below carefully.

Chemicals have to be stored in a dry and cool atmosphere at a temperature of 10deg. C (50 deg.F) to 20 deg. C (68 deg. F).

Before use be sure that the shelf life of the chemicals has not been exceeded.

Because all calculations about quantity of chemicals are based on a temperature of 20 deg. C (68 deg. F) make sure that the chemicals have at least this temperaturebefore starting refoaming.

Make sure that all materials have a temperature of at least 16. C (61 deg. F) and notexceeding 40 deg. C (104 deg F).

To achieve good adhesion of the foam all materials are to be clean and carefully coated with an adhesive primer.

7-4.1 Injection of foaming machine.

If a foaming machine is available in the repair shop, this should always be used for re-foaming after repair on reefer containers.

The advantages of the foaming machine compared to manual foaming are:

- holes for fasteners are used for injection of foam.

- Easy injection of additional foam, of the refoamed area is not completely filled.

- Mixing of the foam components is easy.

-Requires less working time, especially when refoaming large areas.

- Closing of injection holes is done quickly using mono bolts.

- STS based on a foaming machine.


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7-4.1.1 Single injection

When using foaming machine it is possible to fill the cavity to be refoamed with only one shot of foam. This is much faster than using multiple injections.However, the pressure and the temperature in the panel can become very high.Strong bracing is therefore required.This method gives the best result, with the best adhesion to the skin of the panel, andthe highest density of the foam.

Procedure

1. Calculate the necessary injection time for filling the cavity. Use the data for your foaming machine.

2. Set the timer on the machine to the required injection time.

3. Inject the foam.

4. When the foam has risen completely, check for unfoamed cavities (air pockets).

5. Inject additional foam if required.

6. When the cavity is completely filled, clean the area for surplus foam.

7-4.1.2 Multiple Injection

The multiple injection method is recommended when foaming around replacement sections in sandwich panels. This method requires several injection and air outlet holes.

Procedure

1. Set the timer on the foaming machine.

2. Inject the foam.

3. Close the injection hole.

4. When foam is visible in an air outlet hole, install the mono bolt.

5. Wait until the foam has stopped expanding, repeat from step 2, until the cavity is filled.

6. When the cavity is completely filled, clean the area for surplus foam.


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INSIDE OUSIDE

INJECTION


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7-4.2 Manual Re-foaming.

Manual refoaming is used when a foaming machine is not available in the repairshop and for small areas only.

The injection of the foam is done through holes, drilled in the panel.

After refoaming the hole is closed by a plug. Holes for fasteners can be used for airescape and for control of the refoaming.

The control is done by checking that foam is coming out of all holes. The holes shall therefore be placed along outer edges, and at the top of the area to be refoamed.

These holes also serve as air escape holes, so air pockets are avoided.

Procedure for refoaming

1. Lay down quantity of chemicals.

2. Mark the mixing bottle for quantity of component A and B

3. Pour component A (Polyol) into the mixing bottle.

4. Fill in component B ( Isocyanate).

5. Shake thoroughly for a period of a period or not less than 20 seconds.

6. Then immediately pour the mixture into the repair area through the injection holes.

7. When surplus foam is coming out of the injection holes, install closing plug.

8. When surplus foam is coming out of the air escape holes install mono bolts.

9. If the foam does not come out of a hole, the foaming is NOT complete. Make additional hole(s), and repeat from step 1.

10. When all holes have been closed, check for air pockets by knocking on the panel. If air pockets are found, make additional hole(s) in the area, repeat from step1.

11. Clean surface of surplus foam


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Manual Re-foaming.

polyol

isocyanateempty

sealant gun

FOAM MATERIALS TOOLS

pour into can two material(each 50%) , MIXING TWO(2) MATERILAS

INJECTION FOAMING.The injection must be carried within 10sec. After mixing the two material.

This manaul foaming method can be used for small area only.


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PHOTOS OF DAMAGES.

Section Top Side Rail , Patching side panel and re-foaming side panel.

Total repalcement front corner post, Patching side panel and Re-foaming side.

Fix ISO dimension, length, diagonal, etc,..Patching side panel, refoaming

Replace rear top header, inner lining, re-foam

April 2009. [email protected] 1Photo

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Section Top Side Rail , Patching side panel and re-foaming side panel.

Section top side rail, side wall ( external & internal), and roof

Patching base panel and re-foaming,fix T-floor


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Section T-floor and reinforcement section flanges.


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Insert post

Section Side&roof foam panel.Section Top side Rail


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Corner cover&inner lining- section or patching

TWIST-LOCK DAMAGE, Repaired by overlapping reinforcement plate

TWIST-LOCK DAMAGE, Repaired by overlapping reinforcement plate


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must use correct material

welding side panel.

GLUE PATCH - should dry any water and fill in all cavaty


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Section top side rail.

Heavy rust top side rail.

Section Bottom Side Rail and Pactching side panel.

Section and Patching,Roof & Side & Top side rail

Broken top cover, Bent roof lining and side lining.


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REEFER CONTAINERS...Repair Manual Reefer Container 6-3. Bottom Side Rail of Aluminum Reefer...

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Transcript of REEFER CONTAINERS...Repair Manual Reefer Container 6-3. Bottom Side Rail of Aluminum Reefer...