Hapag-Lloyd Container Linie Container Inspection Manual

Version 1.0 1April 2006

Container Inspection Manual

Scope
This Manual is based on the Hapag-Lloyd Repair and Inspection Guidelines as well as additional Instructions generated from know-how and experience during the past decades of Container operation. The purpose of this Manual is to assist Hapag-Lloyd M&R Inspectors to evaluate which damages to a Container under Hapag-Lloyds custody require repair and which damages are to be considered acceptable and as such does NOT require repair. Furthermore the manual will recommend repair methods for individual damages indicated. However, it is not possible to describe every kind of damage/repair in this guideline. As such the local Inspector is invoked to be able to make a decision based on COMMON SENSE. In case of doubt, please contact Hapag-Lloyd Container Engineering Department (2812) for assistance.

Container Inspection Manual

Introduction
GENERAL Items not specifically detailed in this Manual are covered by this general introduction only if they require repair; The tolerances / permitted damages listed are not the minimum necessary to meet basic requirements but are selected to ensure the container is serviceable while minimizing the need for repair and thereby preserving asset life; The repair method selected should be the most economical and suit the particular repair location

Container Inspection Manual

Introduction
ACCEPTABLE DAMAGE This is defined as damage that is not to be repaired and includes: All flange damages, unless the structural integrity of the container is compromised; Deformation of structural members up to ISO +10mm on the side face and ISO +5mm on the end face; Previous repairs should not be reworked unless the structural integrity of the container is compromised or it is unsuitable for cargo.

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Introduction
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 Customs Convention is violated; There is a reduction in the internal height dimension by more than 70mm and/or the internal width/length dimension by more than 50mm; The container is unsuitable for cargo; Cracks in welds are present unless otherwise stated; Corrosion which causes loss of structural integrity

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Introduction
WEAR & TEAR This is defined as unavoidable change or deterioration of the condition of the container brought about by routine operational use and includes: Corrosion; General paint deterioration; Deterioration of door gaskets and fittings; Deterioration of door fixings arising from deterioration of doors; Floor de-lamination resulting from routine cargo loading and unloading cycles

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Introduction
MANUFACTURING DEFECTS Manufacturing defects or suspected manufacturing defects are to be reported to Hapag Lloyd Container Engineering Department (2812).

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Bottom side rails

Holed, cut, torn, broken, cracked, deformation exceeding 50mm. Flange dented, cracked, or cut, NOT going into radius or being in the weld joint to corner post or corner casting. Flange, cracked, or cut, or broken in the weld joint to corner casting, or going into web radius. Weld or straighten, or straighten and weld, or insert, or section, or renew. No action required. Straighten and weld, or insert.

Bottom side rail dented less than 50 mm, No action required!

8

Bottom side rail improper repaired (weld seam broken). Rework or insert required!

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Bottom side rails

Example of Hapag-Lloyd Bottom side rail reinforcement with notched lower bottom side rail and cross member flanges

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Front and Rear sill

Holed, cut, torn, broken, cracked, deformation exceeding 50mm. Flange dented, cracked, or cut, NOT going into radius or being in the weld joint to corner post or corner casting. Flange, cracked, or cut, or broken in the weld joint to corner casting, or going into web radius. Weld or straighten, or straighten and weld, or insert, or section, or renew. No action required. Straighten and weld, or insert.

Front sill dented if less than 50 mm. No action required!

10

Rear sill dented (and cut) more than 50 mm. Repair by inserting recommended!

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Cross member
Web holed, cut, torn, broken, cracked Web deformed in excess of 75mm Web upper flange separated from floor by more than 10mm Bowed up by more than 50mm Weld or straighten, or straighten and weld, or insert, or section, or renew. Straighten, or renew. Straighten and fasten, or renew. Straighten, or renew.

Cross member flange and web cut. Replacement required!

11

Cross member web deformed < 75mm. Replacement is required!

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Fork lift pocket & gooseneck tunnel assembly

Top plate separation from floor in excess of 10mm or floor screws ineffective Web holed, cut torn, or cracked in excess of 500mm or extending into a weld connection Lower flange connection to bottom side rail, holed, cut, torn, cracked extending into web radius Top plate pushed up in excess of 50mm, cut torn or broken Strap broken, cracked, cut, torn, missing Weld or straighten, or straighten and weld, or insert, or renew. Weld, or straighten and weld, or insert, or renew Weld, or straighten and weld, or insert, or section, or renew Straighten or weld, or straighten and weld, or insert, or renew Weld, or straighten and weld, or replace

> 500 mm

Fork lift pocket web cut less than 500 mm. No action required!
12

Fork lift pocket strap missing. Replacement required!

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Floor planks and panels

Gouge greater than 15mm deep irrespective of length Gouge more than 6mm deep and greater than 150mm wide irrespective of length De-lamination or other damage (affecting floor strength) Difference in height between adjacent planks/panels greater than 10mm Section or renew Section or renew Replace, if structural integrity is compromised Refasten

Floor plate broken. Replacement required!

13

Floor de-laminated. Replacement required!

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Floor fastenings
Protruding Three or more adjacent broken/loose, missing fasteners Refasten Refasten or replace

Protruding Floor screw. Refasten is required!

14

More than three adjacent screws broken off. Replacement is required (also the cross member needs to be replaced)!

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Top side rails

Holed, cut, torn, broken, cracked, deformation exceeding 30mm. Weld or straighten, or straighten and weld, or insert, or section, or renew.

Top side rail dented in excess of 30 mm. Repair by sectioning the damaged part is required!
15

Top side rail dented less than 30 mm. No action required!

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Front and Rear headers

Holed, cut, torn, broken, cracked, deformation exceeding 40mm. Weld or straighten, or straighten and weld, or insert, or section, or renew.

Rear header dented less than 40 mm. Repair only when interfering with door operation or broken!
16

Front header dented in excess of 40 mm. Replacement required!

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Front and Rear headers

Holed, cut, torn, broken, cracked, deformation exceeding 40mm. Weld or straighten, or straighten and weld, or insert, or section, or renew.

Front header flange cut. No action required!

17

Front header flange cut. No action required!

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Corner posts
Holed, cut, torn, broken, cracked Dents exceeding 20mm Weld or straighten, or straighten and weld, or insert, or renew. Straighten, or insert, or renew.

Straighten, or insert, or renew. Bent, bow or deformation, if exceeding outer faces of corner castings by +5mm on end face or +10mm on side face

Corner post dented in excess of 20 mm and out of ISO dimensions. Insert required!
18

Rear corner post dented in excess of 20 mm and interfering with door operation. Replacement required!

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Corner posts
Holed, cut, torn, broken, cracked Dents exceeding 20mm Weld or straighten, or straighten and weld, or insert, or renew. Straighten, or insert, or renew.

Straighten, or insert, or renew. Bent, bow or deformation, if exceeding outer faces of corner castings by +5mm on end face or +10mm on side face

Corner post dented less than 20 mm and . No action required!

19

Front corner post dented in excess of 20 mm. Replacement required!

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Corner posts
Examples of acceptable Corner post Inserts

20

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Corner posts
Examples of NOT acceptable Corner post Inserts

21

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Corner castings
Cracked, deformed, broken Deformation preventing correct twistlock operation Replace Replace

Corner casting broken. Replacement required!

22

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Side/front/roof panel incl. header plate

Dents into cube which reduce the internal width by more than 50mm from the inner corrugation including multiple dents, or 70mm from the floor to the roof inner corrugation Holed, torn or cut Dents exceeding the outer face or corner casting +40mm Straighten, or straighten and weld, patch, insert or renew

Weld, or straighten and weld, patch, insert or replace Straighten, or straighten and weld, patch, insert or renew

Side panel out of ISO dimensions by more than 40 mm. Repair by straighten required!
23

Side panel dented in excess of 50 mm into cubic capacity. Repair by straighten required!

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Doors
Holed, cut, torn, broken, cracked component or weld, or deformation affecting security and operation of doors Missing/broken or loose parts which affect door operation or watertightness Weld or straighten, or straighten and weld, or patch, or insert, or renew Replace or refix

Handle retainer bolt loose. Re- fasten required!

24

Locking bar guide cut but not affecting door operation. No action required!

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Doors
Holed, cut, torn, broken, cracked component or weld, or deformation affecting security and operation of doors Missing/broken or loose parts which affect door operation or watertightness Weld or straighten, or straighten and weld, or patch, or insert, or renew Replace or refix

Loose door gasket affecting the watertightness. Re- fasten required!

25

Door gasket cut and improperly repaired Insert required!

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J Bars
If interfering with door operation Weld or straighten, or straighten and weld, or insert

J Bar affecting door operation. Insert required!

26

J Bar affecting door operation. Insert required!

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Door hold backs (Tie backs)

Missing Renew

Door hold back missing. Replacement required!

27

Door hold back missing. Replacement required!

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Data plates
Loose or missing plates Refasten or replace

Data plate (Timber treatment) missing. Replacement required!

28

Example of an intact Hapag-Lloyd Data plate.

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Lashing devices
Broken, cracked, missing or non functional Straighten, or weld, or replace

Lashing bar broken. Re-welding required!

29

Lashing ring not functional. Repair required!

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Surfaces
Glue (Sticky) Odour, infestation, debris, contamination that can be transferred Vents blocked, loose, damaged and not weathertight Graffiti / foreign markings - offensive/possibly offensive Clean and/or paint Clean and/or remove Repair/ replace Repair/remove

Glue and paper rests remaining on inner panel. Removal required!

30

Rope remaining on Lash ring. Removal required!

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ISO decals
Missing or illegible Replace

Container number and weight table missing. Renewal required!

31

ISO Container Number improperly applied. Remove and replace!

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Rain gutters
Damage affecting door operation or exceeding outer face of corner casting +10mm Straighten or remove

Rain gutter dented, not affecting door operation. No action required!

32

Rain gutter out of ISO, but not exceeding 10 mm. No action required!

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Hazardous Label
Remaining on panels Remove

Rests of IMDG Label remaining on Panel. Complete removal required!

33

IMDG Label remaining on Panel. Removal required!

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Roof bows (Open Top Container)

Holed, cut, torn, broken, cracked Dents into cube which reduce the internal height by more than 70mm Missing Weld, straighten and weld or replace Straighten or replace Replace

Row bows dented in excess of 70 mm and/or holder broken. Straighten and renewal required!
34

Several roof bows missing. Complete replacement required!

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Tarpaulin (Open Top Container)

Cut, holed Repair or replace

Old Tarpaulin patch (not weather tight). Repair required!

35

Tarpaulin cut. Repair or replacement required!

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Tarpaulin (Open Top Container)

Cut, holed Repair or replace

Wrong Tarpaulin not in accordance with Customs Regulations. Replacement required!

36

Tarpaulin cut. Repair or replacement required!