Certification of Cargo Containers
Rules for Certification of Cargo Containers
Rules for
Certification of
Cargo Containers
.
Rules for
Certification of
Cargo Containers
1998
American Bureau of Shipping
Incorporated by Act of the Legislature of the State of New York 1862
Copyright © 1998
American Bureau of Shipping
Two World Trade Center, 106th Floor
New York, NY
10048 USA
.
Foreword
The American Bureau of Shipping, with
the aid of industry, published the first edition of these Rules as a Guide in
1968. Since that time, the Rules have reflected changes in the industry brought
about by development of standards, international regulations and requests from
the intermodal container industry. These changes are evident by the inclusion
of programs for the certification of both corner fittings and container repair
facilities in the fourth edition, published in 1983.
In this fifth
edition, the Bureau will again provide industry with an ever broadening scope
of services. In response to requests, requirements for the newest program, the
Certification of Marine Container Chassis, are included. Additionally, the
International Maritime Organization’s requirements concerning cryogenic tank
containers are included in Section 9.
On 21 May 1985,
the ABS Special Committee on Cargo Containers met and adopted the Rules
contained herein.
On 6 November 1997, the ABS Special
Committee on Cargo Containers met and adopted updates/revisions to the subject
Rules. The intent of the proposed changes to the 1987 edition of the ABS “Rules
for Certification of Cargo Containers” was to bring the existing Rules in line
with present design practice. The updated proposals incorporated primarily the
latest changes to IACS Unified Requirements and ISO requirements.
The effective date of the Rule changes is 13 May 1998 in
line with other 1998 ABS Rules.
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Contents
Rules for Certification of Cargo Containers
SECTION
1 Conditions of
Certification........................................................................................................... 1 2 Design
Review............................................................................................................................... 5 3 Materials and
Fabrication............................................................................................................. 7 4 Quality
Assurance.........................................................................................................................11
5 Definitions.....................................................................................................................................13
6 Design
Considerations ..................................................................................................................15
7 Testing............................................................................................................................................33
8 Marking..........................................................................................................................................37
9 Tank
Containers............................................................................................................................43
10
Thermal Cargo
Containers...........................................................................................................49
11
Container
Surveys.........................................................................................................................55
12
Certification of Container Repair
Facilities................................................................................57
13
Certification of Container Refrigeration
Machinery...................................................................59
14
Certification of Carbon Steel Container Corner
Castings..........................................................63 15 Certification
of Container Chassis...............................................................................................65
Appendices
Section 8
Appendix A Approval plates required for
containers certified in accordance with the International Convention for Safe
Containers (CSC) and the International Convention for the Transport of Containers
under Customs Seal (TIR).
Section 15
Appendix B Association of American
Railroads Container Chassis for TOFC Service Standard Specification M-943-80.
Appendix C
International Road Federation Limits of Motor Vehicle Sizes and Weights.
Section 1 Appendix
D International Convention for Safe
Containers (CSC).
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Section
1 Conditions of Certification
1.1 Certification
The Certification process consists of
a) the development of Rules, Guides, standards and other criteria for the
design and construction of containers, for materials and equipment, b) the
review of design and survey during and after construction to verify compliance
with such Rules, Guides, standards or other criteria and c) the issuance of
certificates when such compliance has been verified.
The Rules, Guides and standards are
developed by Bureau staff and passed upon by committees made up of container
manufacturers, naval architects, marine engineers, shipbuilders, engine
builders, steel makers and by other technical, operating and scientific
personnel associated with the worldwide maritime and container industry.
Theoretical research and development, established engineering disciplines, as
well as satisfactory service experience are utilized in their development and
promulgation. The Bureau and its committees can act only upon such theoretical
and practical considerations in developing Rules, Guides and standards.
1.3 Certificates
and Reports
Plan review and surveys during and after construction are
conducted by the Bureau to verify to itself and its committees that a container
is in compliance with the Rules, Guides, standards or other criteria of the
Bureau and to the satisfaction of the attending Surveyor. All reports and
certificates are issued solely for the use of the Bureau, its committees, its
clients and other authorized entities.
1.5 Approval of the Prototype Container
Certification will be based primarily upon the container
meeting the design considerations in Section 6, the performance tests in
Section 7 for all containers, and additional design considerations and tests in
Sections 9 and 10 for tank containers and thermal containers. When a prototype
container meets the requirements of the Rules and has passed the required tests
the Prototype Test Certificate will be issued.
1.7 Certification
of Production
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Certification of the production units will be based upon the satisfactory
conclusion of container plan review, prototype approval, the production tests
required by Section 7, the acceptance of the manufacturer’s quality control
procedures and the survey of each container. Additional tests are required for
tank containers and for thermal containers as set forth in Sections 9 and 10.
The production units, when considered acceptable to the Bureau, will be
certified and a Container Production Certificate issued.
When a container is accepted for general
service a decal, as shown in Figure 1.1, signifying that the container is in
compliance with the Rules, is to be affixed to the container. When a container
is accepted for special service under 1.17.2, a decal as shown in Figure 1.2
signifying that the container meets the requirements for its intended service
is to be affixed to the container.
1.9 Optional
Inspection
When requested by an Owner the Bureau may also inspect
containers in accordance with Owner specifications in addition to the
inspection required by the Rules for certification.
1.11 Representations
as to Certification
Certification is a representation by
the Bureau as to the structural fitness for a particular use or service in
accordance with its Rules, Guides and standards. The Rules of the American
Bureau of Shipping are not meant as a substitute for the independent judgment
of professional designers, naval architects and marine engineers nor as a
substitute for the quality control procedures of shipbuilders, container
manufacturers, steel makers, suppliers, manufacturers and sellers of marine
materials, machinery or equipment. The Bureau, being a technical society can
only act through Surveyors or others who are believed by it to be skilled and
competent.
The Bureau represents solely to the
container manufacturer, container Owner or client of the Bureau that when
certifying it will use due diligence in the development of Rules, Guides and
standards and in using normally applied testing standards, procedures and
techniques as called for by the Rules, Guides, standards and other criteria of
the Bureau. The Bureau further represents to the container manufacturer,
container Owner or other client of the Bureau that its certificates and reports
evidence compliance only with one or more of the Rules, Guides, standards or
other criteria of the Bureau in accordance with the terms of such certificate
or report. Under no circumstances whatsoever are these representations to be
deemed to relate to any third party.
1.13 Responsibility
and Liability
Nothing contained in any certificate or report is to be
deemed to relieve any designer, builder, Owner, manufacturer, seller, supplier,
repairer, operator, other entity or person of any warranty express or implied.
Any certificate or report evidences compliance only with one or more of the
Rules, Guides, standards, or other criteria of the American Bureau of Shipping
and is issued solely for the use of the Bureau, its committees, its clients, or
other authorized entities. Nothing contained in any certificate, report, plan
or document review or approval is to be deemed in any way a representation or
statement beyond those contained in the paragraphs entitled, “Representations
as to Certification.” The validity, applicability and interpretation of any
certificate, report, plan or document review are governed by the Rules, Guides,
and standards of the American Bureau of Shipping who shall remain the sole
judge thereof.
1.15 Authorization
The Committee of the American Bureau of Shipping has
authorized the Surveyors to the Bureau to carry out the necessary surveys, when
requested to do so by the owners or builders of cargo containers, to insure
compliance with the following requirements and to certify compliance.
1.17 Scope
1.17.1 General Service
These Rules are intended to apply to new cargo containers
which are:
Of a permanent
character and accordingly strong enough to remain serviceable for a reasonable
period after repeated use.
Specially
designed to facilitate the carriage of goods, by one or more modes of
transport, without intermediate reloading.
Fitted with devices permitting their
ready handling, particularly their transfer from one mode of transport to
another.
Containers which do not meet the criteria stated herein will
be specially considered.
1.17.2 Special Service
The Bureau is prepared to consider special modified
requirements applicable to cargo containers where it can be shown that the
special requirements are consistent with the intended service conditions. In
such case a prototype is to meet performance tests based on intended service.
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1.19 Containers Not Built Under Surveillance
Individual existing containers, or sample units from an
existing container series, which have not been built to the requirements of
these Rules, but which are submitted for certification, are to be subjected to
testing in accordance with the requirements of these Rules. Where found
satisfactory, they will be certified accordingly.
1.21 Approval
of Modified Containers
The owner of a container which has been approved in
accordance with the requirements of the CSC and has been modified in a manner
resulting in structural changes is to notify the Bureau of those changes. The
Bureau may require retesting of the modified container as appropriate prior to
recertification.
1.23 Loading,
Handling, and Securing
These Rules are published on the understanding that
responsibility for securing containers, for control of stacking loads, and for
reasonable handling and loading, as well as for avoidance of distributions of
weight which are likely to set up abnormally severe stresses in containers,
does not rest upon the Committee, or the Bureau.
1.25 Governmental and
Regulatory Agency Requirements
When authorized by an Administration
signatory to international conventions, and upon request, the certification
procedure may be extended and containers surveyed for compliance with the
provisions of the conventions, and certified thereto in the manner prescribed.
The International Convention for Safe
Containers (CSC) is an international agreement to which ABS is authorized to
certify containers. As an assist to the reader, the convention is reproduced in
Appendix F.
1.27 Disagreement
and Interpretation
Disagreement regarding the interpretation of the Rules, is
to be referred to the Bureau for resolution. In case of disagreement between
the Owners or builders and the Surveyors to the Bureau regarding the material,
workmanship, extent of repairs, or application of these Rules relating to any
container certified or proposed to be certified by this Bureau, an appeal may
be made in writing to the Committee, who will order a special survey to be
held. Should the opinion of the Surveyor be confirmed, the expense of this
special survey is to be paid by the party appealing.
be affixed to each
Bureau-approved cargo container that meets the requirements of its intended
service.
.
Design
Review Section
2
Section
2 Design Review
2.1 Application
for Certification
The application for the
certification of containers is to include a statement that the containers will
be built in conformance to these Rules; that they will be manufactured under a
quality control program acceptable to the Bureau; that they will be available
for inspection during manufacture and testing and that they will be tested in
accordance with prescribed procedures. The application is also to affirm that
changes in design, materials, or fabrication methods will not be made without
written approval.
Each application is to be
accompanied by plans and data of the container to be certified. The plans are
to delineate the arrangements and structural details of the containers as they
are to be built. In addition to the plans a test agenda is to be submitted
which details the actual load values and identifies the load medium to be used
during the testing of the prototype.
2.3 New
Design Series
For the application of each design series to be
certified, plans and data including at least the following are to be submitted:
ABS Application form—one copy*
ABS Container data form—one copy*
ABS Data Form
Supplement for Thermal Containers [if applicable]—one copy*
ABS Data Form Supplement for Tank Containers [if
applicable]—one copy* ABS Material identification form—four copies* Following
drawings—four copies each:
General arrangement
Sub-assemblies
Detail of components
Markings, including data plates
Prototype test agenda—one copy
Quality control procedures—one-time
requirement for each manufacturing facility.
*To assist clients in providing the
information necessary for the certification of the container the Bureau has
printed application forms, available upon request.
2.5 Approved
Design Series
For the application of additional units to be certified to
an approved design series, the submittal is to include at least the following:
ABS Container Data form—one copy*
ABS Data Form
Supplement for Thermal Containers [if applicable]—one copy*
ABS Data Form
Supplement for Tank Containers [if applicable]—one copy*
Marking drawing—if owner has
changed—four copies
2.7 Changes
When changes are being made to an application or to an
approved design series, the submittal is to include at least the following:
ABS Container Data form—one copy*
ABS Data Form
Supplement for Thermal Containers [if applicable]—one copy*
ABS Data Form Supplement
for Tank Containers [if applicable]—one copy*
ABS Material Identification form—one copy*
Design comparison table
Marking
drawing—if owner has changed—four copies
General assembly,
subassembly and detail drawings as appropriate showing any revision from
original design—four copies
All changes will be reviewed and if the
modifications are deemed significant retesting of those parts of the container
affected by the modification may be required.
2.9 Certification to Other Requirements
When the application includes a request for certification to
governmental requirements, international conventions, or other standards, the
submittal is to include the necessary information required for the reviews.
Design
Review Section
2
.
Section
3 Materials and Fabrication
3.1 Material
Standards
Except where specifically approved, all structural materials
are to conform to an established specification or recognized national standard.
In the selection of materials due regard is to be given to established
practices in the country in which the material is produced and the purpose for
which the material is intended, the expected service, and the nature of
construction of the container.
3.3 Welders
The Surveyor is to be satisfied that the welders are
proficient in the type of work that they are called upon to do either through
requiring any or all of the tests outlined in the following paragraphs or
through due consideration of the system, training apprenticeship, plant
testing, inspection, etc.
3.5 Qualification
The tests, if required for
qualification in the various positions for different materials and thicknesses,
are given in Figures 3.1 through 3.4. Test positions are flat (F), horizontal
(H), vertical (V), and overhead (OH). Testing in V and OH qualifies the welder
for all positions.
Alternatively, upon the request of the
employer, the welder may be qualified by use of radiography tests except for
gas metal arc welding with the shortcircuit transfer technique, for which the
tests shown in Figures 3.1 through 3.4 are required.
FIGURE 3.1 Square Groove Butt Joint
Material: |
6.0 mm (¼ in.) Sheet to
Casting |
Test Position: |
F H V OH |
Qualifies for: |
F F, H F, H, V F,
H, OH |
Specimen: The
plate is to be 150 mm (6 in.) x 150 mm (6 in.). The weld is to be a minimum of
150 mm (6 in.) in length and is to be welded from one side only. The root gap
is to be 2.0 mm (5/64 in.).
Test:
The corner casting is to be secured and the sheet is to be bent 180º towards
the corner fitting. The axis of the bend is to be parallel to the axis of the
weld. Criterion: A weld will be
considered satisfactory if:
a. No
cracks are evident after bending.
b. Due
to the severity of the test, cracks do occur; but the fractured face shows no
evidence of defects, and the throat is equal to or greater than the thickness
of the sheet steel. Breaks in the base metal shall not be cause for weld
rejection.
FIGURE 3.2 T-Joint Fillet Weld
Material: |
3.0 (Z,
in.) Sheet to Casting and 6.0 (Zv in.) Sheet to Casting |
|
Test Position: |
F H V |
OH |
Qualifies for: |
F F, H F, H, V |
F, H, OH |
Specimens:
The plates are to be 150 mm (6 in.) x 150 mm (6 in.). The welds are to be a
minimum of 150 mm (6 in.) in length. The throat size of the fillet weld is to
be equal to the thickness of the thinner material.
Test: The corner
fitting is to be secured and the sheet is to be bent back and forth until
failure.
Criterion: A weld
will be considered satisfactory if the fracture surface shows complete fusion
at the faying surface.
FIGURE 3.3
Square Groove Butt Joint
Material: 1.2 mm (.048 in.) to
1.2 mm (.048 in.) sheet
Test Position: F H V OH
Qualifies for: F F, H F, H, V F,
H, OH
Specimen: The
plates are to be 150 mm (6 in.) x 150 mm (6 in.). The weld is to be a minimum
of 150 mm (6 in.) in length. The root gap is to be 1.0 mm (C
v in.).
Test: One sheet is
to be secured and the other is to be bent 180º back towards the held end. The
axis of the bend is to be parallel to the axis of the weld.
Criterion: A weld
will be considered satisfactory if:
a. No
cracks are evident after bending.
b. Due
to the severity of the test, cracks do occur; but the fractured face shows no
evidence of defects, and the throat is equal to or greater than the thickness
of the sheet steel. Breaks in the base metal shall not be cause for weld
rejection.
FIGURE 3.4 Lap Joint Fillet Weld
Material: |
1.2 mm (.048 in.) to 1.2 mm
(.048 in.) Sheet and 2.0 mm (.080 in.) to 4.0 mm
(.157 in.) Sheet |
Test Position: |
F H V OH |
Qualifies for: |
F F, H F, H, V F,
H, OH |
Specimen: The top
plates are to be 150 mm (6 in.) x 150 mm (6 in.). The bottom plates are to be a
minimum of 200 mm (8 in.) x 200 mm (8 in.) The welds are to be a minimum of 150
mm (6 in.) in length. The throat of the fillet weld is to be equal to the
thickness of the thinner material.
Test: A cold
chisel is to be wedged between the two sheets until failure.
Criterion: A weld
will be considered satisfactory if the fracture surface shows complete fusion
at the faying surface.
Quality Control Section
4
Section
4 Quality Control
4.1 Quality
Control Manual
The principal manufacturers engaged in the production of
containers are to submit a quality control manual which gives in detail those
inspections and controls which are to be followed to assure that the quality of
the production units are comparable to that of the prototype. The quality
control manual is to contain the information listed in 4.1.1 through 4.1.5.
This manual is to be initially submitted to ABS for review in order that
compliance may be verified with this section of the Rules. Subsequent to a
satisfactory review by ABS, the manufacturing facility is subject to an audit
by the attending Surveyor to confirm compliance with the quality control
procedures outlined in the submitted manual. All changes or revisions to the
manual including any quality control procedures are to be submitted to the
Bureau for review.
4.1.1 Description of Organization A
description of the manufacturers organization consisting of management,
purchasing, production, and quality control functions is to be shown in the
manual. Evidence to support adequate manning levels of inspection at the
various manufacturing stages is to be provided by the manufacturer.
4.1.1.1 The line of responsibility for the
quality control function is to be independent from the production function.
4.1.1.2 The quality control function is to be
shown to be adequately staffed in order to maintain control of the purchased
materials, manufacturing processes, testing as applicable, and final acceptance
of the finished container.
4.1.1.3 Arrangements for introducing approved
design and production changes to ensure that they are acted upon at the
appropriate production stage are to be addressed in the manufacturer’s manual
or procedures.
4.1.1.4 The manual or procedures is to address
the manufacturer’s system of performing internal audits and corrective actions.
4.1.1.5 It is to be shown in the manual or procedures
that compliance with these Rules is evidenced during the ABS review process and
demonstrated to the attending Surveyor during periodic audits of the
manufacturer.
4.1.2 Material
Identification Methods are to be established and covered in the manual or
procedures to control and identify all material, including methods for welding
electrode identification. Structural material identification arrangements such
as mill test reports (MTR’s), material purchase orders, etc. are to be
sufficient to enable the MTR to be traceable to the material.
4.1.2.1 Arrangements to ensure that supplies and
services from a sub-supplier meet with the design requirements are to be
addressed in the manual or procedures.
4.1.2.2 Identifiable test data for materials and
components is to be made available for the attending Surveyor.
4.1.2.3 Arrangements are to be made by the
manufacturer to demonstrate proper storage of stock materials and spare parts
which is consistent with good industry practice.
4.1.3 Workmanship Quality
Methods are to be established to assure workmanship of
consistently acceptable quality. Jigs or fixtures suitable for maintaining
dimensional accuracy during repeated use are to be provided at the mainframe
assembly points or locations. The manual or procedures are to address that the
jigs or fixtures are periodically verified by the manufacturer’s quality
control function.
4.1.4 Control Records
The procedures for maintaining records are to be adequate to
assure the proper identification of material and satisfactory checks on
workmanship.
4.1.4.1 A system of documentation at the stages
of manufacturing containers is to be covered in the manufacturer’s manual or
procedures. The system employed is to be demonstrated to the attending
Surveyor. This system may be comprised of traveler forms, inspection checklists
or procedures evidencing inspections being performed at the various stages of
manufacturing.
4.1.4.2 The records of inspection, tests, and
results of examinations and corrections are to be complete and reliable for
each container. The record of inspection is to contain the manufacturer’s
identification numbers, dates of delivery and names and addresses of
purchasers.
Quality
Control Section
4 |
4.1.5 Fabrication
Quality Control Methods The weld procedures and inspection techniques
employed in the fabrication of containers are to be to the satisfaction of the
attending Surveyor. Special attention is to be given to the methods for proving
the adequacy of the corner fittings, and their attachment to the main
structural members. The quality of corner fittings may be verified by
certification in accordance with Section 14. In any circumstance, copies of the
certified MTR’s for the corner fittings are to be made available to the
attending Surveyor.
4.1.5.1 All stages of the container
manufacturing as shown above together with the final dimensional examinations
necessary are to be under the responsibility of the quality control function.
4.1.5.2 The rejection procedure and rejected
component identification arrangements are to be clearly defined by the
manufacturer.
4.1.5.3 All welding to be performed in the
fabrication of the container or its subassemblies is to be carried out by
qualified personnel in the positions for which they are qualified to weld.
4.2 Quality
Control Surveillance
The manufacturer’s production facilities and quality control
methods are to be available for audit by the Surveyor during his periodic
visits. When, in the judgment of the Surveyor, unacceptable workmanship, faulty
material, or inadequate quality control procedures are evident, certification
may be suspended pending corrective action to the Surveyor’s satisfaction.
4.2.1 All weld
procedure specifications (WPS), procedure qualification records (PQR), and
welder’s performance qualification records are to be in accordance with
recognized standards and are to be reviewed to the satisfaction of the
attending Surveyor.
4.2.2 All
nondestructive examinations performed by the manufacturer are to be
accomplished by personnel qualified to conduct such inspections in accordance
with recognized standards. Where nondestructive examinations are performed, it
is to be demonstrated that such testing is properly recorded by the
manufacturer and found to be to the satisfaction of the attending Surveyor.
4.3 Factory
Approval Certificate
Manufacturing and testing facilities for proving prototype
and production containers are to be approved by ABS. The scope of the approval
process will include that the following steps be completed:
4.3.1 The
manufacturer is to submit a written application for ABS Factory Approval.
4.3.2 The
manufacturer is to submit three (3) copies of their quality control manual and
applicable procedures as listed in these Rules. Supplemental information in the
way of company brochures, profile, description of facilities, equipment,
storage, process flow diagrams, etc. may be provided for reference purposes.
4.3.2.1 A review letter is issued to the manufacturer
describing the evaluation of all elements of the manufacturer’s system
governing the control and quality of the product.
4.3.3 An audit of
the manufacturer’s facility is performed after issuance of the ABS review
letter to the manufacturer. This audit is performed by an ABS Surveyor working
in close cooperation with the manufacturer’s representative, to confirm
implementation of the quality control system.
4.3.4 The
approval of the manufacturer’s facility is contingent upon successful
completion of the review process in such a manner that there are no outstanding
comments and upon successful completion of the initial audit by an attending
Surveyor.
4.3.5 The
validity of the Factory Approval Certificate is subject to the continued
maintenance of conditions under which the approval was granted by ABS. Periodic
audits of the manufacturer are to be performed on an annual basis.
Definitions Section
5 |
Section
5 Definitions
5.1 General
The following definitions for symbols and terms are used
throughout these Rules.
5.3 Maximum
Gross Weight (R)*
R or rating is the
maximum allowable combined mass of the container and its cargo to which the
container is tested and is expressed in kilograms and pounds.
5.5 Design
Gross Weight
The design gross weight is the weight rating on which the
structural design of the container is based, and is to be equal to or greater
than the maximum gross weight.
5.7 Tare (T)
T or tare is the mass of the empty
container, including its normal complement of fittings, equipment and devices
and is expressed in kilograms and pounds.
5.9 Payload
(P)
P or payload is the difference between R and T and is expressed in kilograms and pounds.
5.11 Design
Load
The design load is the minimum statically applied load which
the container is to be designed to withstand.
5.13 Design
Load Factor
The design load factor is a factor which takes into account,
insofar as practicable, the static and dynamic loads and other applicable
considerations.
5.15 Reference
Mass
The reference mass is that mass which is to be multiplied by
the design load factor to obtain the design load.
*When Assembly Resolution A.737(18) of the
International Convention for Safe Containers (CSC) comes into force the term “maximum gross weight” will become “maximum operating gross mass.” The CSC
and Resolution A.737(18) have been reproduced in Annex D.
5.17 Floor
Load
The floor load is the combined static and dynamic load
imposed on the floor by the cargo and by the wheels of handling equipment.
5.19 End
Load
The end load is the combined static and dynamic load imposed
by the cargo on the container walls or doors, or both, which are perpendicular
to the longitudinal axis of the container.
5.21 Side
Load
The side load is the combined static and dynamic load
imposed by the cargo on the container walls or doors, or both, which are
perpendicular to the transverse axis of the container.
5.23 Roof
Load
The roof load is the combined static and dynamic load
imposed on the roof of a container.
5.25 Specified
Dimensions
The specified dimensions of the length, width, and height of
a container are the maximum allowable outside dimensions.
5.27 Prototype
A prototype is a representative unit of a series of
identical containers built under conditions which duplicate, insofar as is
practicable, the conditions under which all of the containers in the series are
to be fitted.
5.29 Production
Units
Production units are identical containers built under
conditions which duplicate, insofar as is practicable, the conditions under
which the prototype was built.
5.31 Corner
Fitting
A corner fitting is a fixture consisting of standard
apertures and faces which provide a common interface for handling and securing
containers.
Certification of Cargo Containers 13 ABS®
Definitions Section
5
.
Certification of Cargo Containers 14 ABS®
Section
6 Design Considerations
6.1 General
Specifications
Construction is to be structurally sound and when
appropriate, weathertight. All fittings and appurtenances are to be within the
maximum outside dimensions of the container. The main frame, corner structures,
sides, and ends are to have sufficient structural strength to remain
serviceable and withstand, without significant permanent deformation, the
static and dynamic loads imposed by lifting the container by top or bottom
corner fittings, the stacking loads, and the impact and racking loads
encountered in normal service. The floor structure is to be strong enough to
support the payload under dynamic loading conditions encountered in normal
service and concentrated fork-lift truck axle loads. The specific design
loading requirements are to be not less than those given in 6.11. The
manufacturer is responsible for designing the container with sufficient
strength to withstand the design loads, and is to include factors of safety
allowing for fatigue, normal wear and tear, manufacturing fabrication
techniques, and material properties.
6.3 Service
Conditions
6.3.1 General
Containers used in multimodal transport should be
serviceable under normal operation in weather conditions ranging from tropical
to arctic zones. Each transport mode has its own operating load requirements
which can be expressed as accelerations in the vertical, transverse or
longitudinal direction.
6.3.2 Marine
Containers operating in the marine
mode are often stowed in vertical stacks within the cells in a ship’s hold.
When stowed in this manner, containers will be restrained at the end frames
against longitudinal and transverse movement by the cell structure. The
reactions of the entire stack of containers are taken through the four bottom
corner fittings of the lowest container. Containers may also be stowed on deck
or in a hold restrained by lashings, deck fittings, or both. Containers are
normally stowed with the longitudinal axis of the container parallel to that of
the ship.
It is assumed that the combined effect of
a vessel’s motions and gravity results in an equivalent 1.8 times gravity for
vertical acceleration, an equivalent 0.6 times gravity for transverse
acceleration, and an equivalent 0.4 times gravity for longitudinal
acceleration, acting individually.
6.3.3 Highway
Containers operating in the highway
mode are carried by container chassis which provide support and restraint
through the bottom corner fittings, the base structure, or through a
combination of the two.
It is assumed that the combined effect of
a vehicle’s motions resulting from road conditions, curves, braking, and
gravity results in an equivalent 1.7 times gravity downward for vertical acceleration,
an equivalent 0.5 times gravity upward for vertical acceleration, an equivalent
0.2 times gravity for transverse acceleration, and an equivalent 0.7 times
gravity for longitudinal acceleration.
6.3.4 Rail
Containers operating in the rail mode are
carried by railcars in two primary systems: container on a flat car (COFC) in
which the container is supported and restrained through the bottom corner
fittings; and trailer on a flat car (TOFC) in which the container and its
chassis are carried as a single unit on the railcar.
It is assumed that the combined effect of
a railcar’s motions resulting from the ride characteristics of the railcar,
switching operations, and gravity results in an equivalent 1.7 times gravity
downward for vertical acceleration, and equivalent 0.3 times gravity for
transverse acceleration, and an equivalent 2.0 times gravity for longitudinal
acceleration.
6.3.5 Terminal
Handling
Handling equipment will subject the container to certain
forces that must be considered when designing a container. The lowering of
containers onto supports produces a dynamic load. It is assumed that the
combined effect of this dynamic load and gravity results in an equivalent 2.0
times gravity downward for vertical acceleration.
6.5 Dimensional
Tolerances
6.5.1 Overall Dimensions
The overall dimensions of the container may vary from the
specified dimensions within the tolerances shown in Figure 6.1. Tolerances for
intermediate specified dimensions may be obtained by interpolation.
6.5.2 Corner Fitting Location Tolerances The
tolerances for the distance between the centers of apertures of corner fittings
for the length, width, and height are to be equal to the tolerances of the
overall dimensions of the length, width, and height.
6.5.3 Diagonal Tolerances
The value of diagonal tolerances K1 and K2 are not to exceed
those given in Figure 6.1.
6.5.4 Measurement Criteria
The dimensions and tolerances apply when measured at a
temperature of 20°C
(68°F).
Measurements taken at temperatures appreciably different are to be adjusted
accordingly.
6.7 Design
Features
6.7.1 Corner Design
A container is to have four top and four bottom corner
fittings, oriented to define the corners of a hypothetical rectangular box.
Figure 6.7 illustrates the recommended dimensions and tolerances of corner
fittings. The dimensions of the corner fittings in Figure 6.7 are the same as
those specified in International Organization for Standardization (ISO)
Standard 1161 Series 1 freight containers—Corner Fittings—Specifications. The
corner fittings are to meet the strength requirements imposed on the containers
by handling methods described in Section 6, but are to be not less than the
strength requirements specified by ISO Standard 1161. Although Figure 6.7
illustrates corner fittings as separate elements of construction which must be
attached to corner posts to form the corner structures of a container, the
figures and references to “corner fittings” in the text do not preclude the use
of corner structures having the necessary apertures as an integral feature of
some other structural member, i.e., post, rail, or crossmember.
6.7.2 Roof
Clearance
The top corner fittings are to protrude a minimum of 6 mm (¼
in.) above the highest point of the roof or upper structure. The transverse and
longitudinal areas adjacent to the top corner fittings may be designed with
reinforcements or “doubler plates” to protect the roof from being punctured
during top lifting operations. Such reinforcements may extend the full width of
the container and not more than 750 mm (29¼ in.) from each end and may not
protrude above the top surface of the corner fitting.
6.7.3 Load Transfer Area
The base structure of a container is to be provided with a
load transfer area in accordance with Figure 6.2, which may be formed by the
bottom surfaces of the crossmembers or corresponding substructure. The plane of
the load transfer area shall be positioned 12.5 mm +5, –1.5 (Zx in. + Czn – Zzn)* above the plane formed
by the lower faces of the bottom corner fittings. Containers fitted with
intermediate transverse members having a spacing of 1000 mm (39C, in.) or less, and
recessed as required, comply with this requirement. Except for the bottom side
rails and the bottom corner fittings, no part of the container is to project
below the plane of load transfer areas. However, the transverse and
longitudinal areas adjacent to the bottom corner fittings may be designed with
reinforcements or “doubler plates” to protect the base from being damaged
during handling and securing operations. Such reinforcements may not extend
more than 470 mm (18½ in.) from the side faces of the bottom corner fittings
and not more than 550 mm (22 in.) from each end of the container with the
bottom surface recessed not less than 5 mm (Czn
in.) above the bottom surface of the corner fitting.
The transfer of load between the underside of the bottom
side rails and the carrying vehicle is not provided for in these Rules. The
transfer of load between side rails, or fork-lift pockets, and handling
equipment should only occur when provisions have been made in accordance with
6.9.1 and 6.9.2.
6.9 Optional
Design Features
6.9.1 Fork-Lift Pockets
Fork-lift pockets may be provided for handling containers in
the loaded or unloaded condition. The fork-lift pockets are to meet the
dimensional requirements specified in Figure 6.3 and pass completely through
the base structure of the container so that lifting devices may be inserted
from either side. Fork-lift pockets are to be provided with a base strap or
equivalent at each end.
6.9.2 Lifting
Areas
Lifting areas may be provided for handling containers in the
loaded or unloaded condition by means of grappler arms or similar devices. The
lifting areas are to meet the location requirements specified in Figure 6.4.
6.9.3 Gooseneck Tunnels
Tunnels may be provided in containers to accommodate chassis
goosenecks. The tunnels are to
*Note This
is the location of the load transfer area, it is not a tolerance. To phrase the
load transfer requirement another way: The load transfer area is to be on a
plane located not less than 11 mm (Mzn in.), nor
more than 17.5 mm (ZZzb in.) above
the plane formed by the lower surfaces of the bottom corner fittings.
meet the dimensional requirements specified in Figure 6.5.
6.9.4 Cargo Securing Devices
Cargo securing devices may be provided in containers for
securing cargo.
6.11 Design
Loading Specifications
6.11.1 General
The design loads on which the requirements of this section
are based take into account, as far as practicable, the dynamic loads likely to
be encountered in container operation. Factors such as characteristics of load
application, load repetition, load reversal and container life are to be
considered in the design of the container. Due regard is to be given to local
stresses resulting from attachment devices used for handling and securing a
container.
6.11.2 Corner Structure Loads—Stacking
Type of load
Concentrated compression
Direction of load
Vertically downward, eccentrically
applied, and equally distributed among the four corner structures.
Reference mass
R
Design load factor
1.8 x 8*; each corner to take one
fourth of the design load.
Basis
The container corner structure is to have sufficient
strength to allow containers to be stacked when transported by vessels.
Vertical accelerations imposed by vessel motions (pitch and heave) are to be
considered. The maximum vertical acceleration caused by combined pitching and
heaving, taking into account the time phasing, may be assumed to be 0.8 g. When
the equivalent dynamic force of 0.8 g is added to the static force of 1.0 g,
the resulting total force may be taken as 1.8 g. It is assumed that the
containers are stacked 9* high in cell guides. Normal cell clearance may be
assumed to be 38 mm (1Zx
in.) in the longitudinal direction and 25 mm (1 in.) in the transverse
direction.
**For 10 ft containers the design
load factor is 1.8 x 5 for 6 containers in a stack.
**For 10 ft containers the lifting forces are to be
applied at an angle of 60º to the horizontal.
6.11.3 Lifting Loads
a. Lifting from Top
Type of load
Concentrated tension
Direction of load
Vertically**
upward, applied tension at pickup points on four top corner fittings. Reference
mass
R
Design load factor
2.0; each corner to take one fourth
of the design load.
Basis
The container top corner fittings and associated components
are to be capable of suspending the loaded container when lifted by any of the
suitable lifting devices.
b. Lifting from Bottom
Type of load
Concentrated tension
Direction of load
Applied at pick-up points on four
bottom corner fittings, acting parallel to the sides, along a line drawn from
the bottom corner fitting through a point located above the roof at midlength
at the following angles [to the horizontal]:
30º for 40 ft containers
37º for 30 ft
containers
45º for 20 ft
containers
60º for 10 ft containers Reference mass
R
Design load factor
2.0; each corner to take one fourth
of the resultant load due to angle based on a vertical component equal to R/2.
Basis
The container bottom corner fittings and associated
components are to be capable of supporting the loaded container when lifted by
any of the suitable lifting devices.
c. Lifting from Fork Lift Pockets
Type of load
Concentrated
Direction of load
Vertically upward
applied at pick-up area Reference mass
R
Design load factor
1.6
Basis
The loaded container is to be capable of being supported on
two horizontal bars each 200 mm (8 in.) wide, projecting 1828 mm (72 in.) into
the fork pocket.
d. Lifting from Grappler Arm Positions
Type of load
Concentrated
Direction of load
Vertically upward, applied at four
lifting positions
Reference mass
R
Design load factor
1.25
Basis
The loaded container is to be capable of being supported at
the four positions where provision has been made for lifting equipment.
6.11.4 Floor Loads
a. Wheeled Vehicle
Type of load
Concentrated wheeled vehicle load
Direction of load
Vertically downward
Reference mass
5460 kg total (2730 kg per wheel)
12000 lb. total (6000 lb. per wheel)
Design load factor
1.0
Basis
The container floor is to be capable of withstanding
concentrated loads imposed by an industrial truck or other vehicle with a
maximum axle loading of 5460 kg (12000 lb.). The minimum wheel width is to be
assumed to be 180 mm (7 in.) with an imprint area not greater than 142 cm2
(22 in.2) per wheel. The minimum wheel center to center distance may
be assumed to be 760 mm (30 in.).
b. Cargo Type of load
Concentrated cargo load
Direction of load
Vertically
downward Reference mass
P
Design load factor
2.0
Basis
The container floor is to be able to withstand a
concentrated cargo load, uniformly distributed from side to side, over any 3 m
(10 ft). The load is considered to be twice the maximum cargo mass (2P) of
which 22680 kg (50000 lb.) is to be uniformly distributed over the mid 3 m (10
ft) with the balance of the load uniformly distributed over the remaining area
of the container floor.
6.11.5 Floor and Rear Panel Loads
a. Cargo Type of load
Uniformly distributed
Direction of load
Longitudinally
outward Reference mass
P
Design load factor
0.4
Basis
Front and rear end panels are to be capable of withstanding
the forces imposed by transport equipment operations, assuming acceleration
during rail car impact. The front end panel is to be of sufficient strength to
withstand the forces encountered during emergency brake application when the
container is transported by highway vehicles.
b. Racking Type of load
Concentrated
Direction of load
Transverse, applied at top corners
Design load
150 kN. (33700 lbf)
Basis
Front and rear end panels are to be capable of withstanding
the racking imposed on the bottom container in a stack when the containers are
carried on deck under conditions affording limited external racking restraint.
6.11.6 Side Panel Loads
a. Cargo Type of load
Uniformly distributed
Direction of load
Transversely
outward Reference mass
P
Design load factor
0.6
Basis
Side panels are to be capable of withstanding forces
imposed by vessel motions. Vessel rolling may be assumed to be isochronous,
simple harmonic type motion. The minimum period for one complete roll may be
assumed to be 13 seconds. The maximum distance of the center of gravity of the
container from the vessel’s roll axis may be assumed to be 13.70m (45 ft).
b. Racking Type of load
Concentrated
Direction of load
Longitudinal, applied at top corners
Design load
75 kN. (16850 lbf)
Basis
Side panels are to be capable of withstanding the racking
imposed on the bottom container in a stack when the containers are carried on
deck under conditions affording limited external racking restraint.
6.11.7 Lashing
Type of load
Concentrated
Direction of load
Longitudinal,
transverse and vertical, applied at corner fittings Design load
Refer to Figure 6.6
Basis
Top and bottom corner fittings are subject to externally
applied loads transmitted through that aperture or face of the corner fitting
perpendicular to the load.
Each corner fitting may be subject to longitudinal,
transverse and vertical forces applied individually or simultaneously, provided
that:
The longitudinal and transverse
components are not to exceed the magnitude specified in Figure 6.6, but in no
case, is the resultant to exceed 150 kN (33700 lbf).
The longitudinal, transverse and vertical
components are not to exceed the magnitude specified in Figure 6.6; but in no
case, is the resultant to exceed 300 kN. (67400 lbf)
The top and bottom corner fittings are to each, in
conjunction with the container structure, be capable to withstanding each of
these loads when applied to any end or side aperture of the external faces. The
container is to be capable of withstanding the reaction to each of the loads
illustrated by Figure 6.6.
6.11.8 Roof Load
Type of load
Uniformly
distributed applied over an area 600 mm x 300 mm (24 in. x 12 in.) located on
the top of the container. Direction of load
Vertically downward
Reference mass
200 kg (440 lb)
Design load factor
1.5
Basis
Container roof structure is to be capable of supporting two
100 kg (220 lb) workers on the container roof.
6.11.9 Base Structure Loads
Type of load
Concentrated
Direction of load
Longitudinal, applied through bottom apertures of bottom
corner fittings Reference mass
R
Design load factor
2
Basis
The base structure is to be capable of withstanding the
forces imposed by transport equipment operations, assuming acceleration during
rail car impact.
6.11.10 Cargo Securing
Device Loads (where provided)
Type of load
Concentrated tension
Direction of load
Applied away from the cargo securing
device in all directions
Reference loads*
10 kN (2200 lbf) for an anchor point
in the base structure; 5 kN (1100 lbf) for a lashing point in any part of the
container other than the
base structure.*
Design load factor
1.5
Basis
Cargo securing devices are to be capable of withstanding
the inertial forces imposed by cargo in transit.
*The reference loads for platform and platform based
containers: 30 kN (6600 lbf) for an anchor point and 10 kN (2200 lbf) for a
lashing point.
FIGURE 6.1
Assembled Corner Fittings—Diagonal Tolerances
Overall length, height and width dimensions are measured
along the appropriate edges.
FIGURE 6.1 (continued)
FIGURE 6.2 Location and Dimensions for Load Transfer
Areas
FIGURE 6.2 (continued)
FIGURE 6.2 (continued)
FIGURE 6.3 Location and Dimensions for Forklift Pockets
Dimensions and Tolerances
|
Fork pockets for loaded and unloaded
containers mm (in.) |
Fork pockets for unloaded
containers only mm (in.) |
A |
2050 ± 50 (81 ± 2) |
— |
B |
355 min (14 min) |
— |
C |
115 min (4½ min) |
— |
A´ |
— |
900 ± 50 (36½ ± 2) |
B´ |
— |
305 min (12 min) |
C´ |
— |
102 min |
(4
min)
FIGURE 6.4 Location and Dimensions for Grappler Lifting
Areas
FIGURE 6.5 Location and Dimensions for Gooseneck Tunnels
FIGURE 6.6 Lashing Loads (Forces)
C1 |
= 100 kn (22400 lbf) |
C2 |
= 150 kn (33700 lbf) |
T1 |
= 150 kn (33700 lbf) |
T2 |
= 150 kn (33700 lbf) |
T3 |
= 1/2 R |
T4 |
= 100 kn (22400 lbf) |
FIGURE 6.7 Top Corner Fitting—Millimeters
Notes
1 Solid
and broken lines (— and - -) show surfaces and contours which must be
physically duplicated in the fitting.
2 Phantom
lines (— - —) show optional walls which may be used to develop a box-shaped
fitting.
FIGURE 6.7
(continued) Top Corner Fitting—Inches
Notes
1 Solid
and broken lines (— and - -) show surfaces and contours which must be
physically duplicated in the fitting.
2 Phantom
lines (— - —) show optional walls which may be used to develop a box-shaped
fitting.
FIGURE 6.7
(continued) Bottom Corner Fitting—Millimeters
Notes
1 Solid
and broken lines (— and - -) show surfaces and contours which must be
physically duplicated in the fitting.
2 Phantom
lines (— - —) show optional walls which may be used to develop a box-shaped
fitting.
FIGURE 6.7
(continued) Bottom Corner Fitting—Inches