40 HCDD
40 HCDD
FOR
STEEL DRY CARGO CONTAINER
40' x 8' x 9'6" 1AAA TYPE
(BOTH ENDS OPEN)
MODEL NO.
: CX02-41BED
SPEC. NO.
: CX02-41BED-S
DATE OF ISSUE
INDEX
Section
1
Title
Page
General .............................................................................................
.....
2
Dimensions
and
Ratings......................................................................
3
Materials...........................................................................................
.....
4
Construction .....................................................................................
....
5
Surface
11
preservation ...........................................................................
6
Markings ..........................................................................................
12
.....
7
Testing
and
13
Guarantee .........................................................................................
14
Inspections ......................................................................
8
....
1.
General
1.1
Scope
This specification will cover the design, construction, materials, testing and inspection
performances of 40' x 8' x 9'6" 1AAA type steel dry cargo containers.
These containers specified herein will be manufactured at appointed factory under strict quality
control by the factory and be approved by the classification society or agency.
1.2
Operational environment
The container will be designed and constructed for carriage of general cargo by marine (on or
below deck), road and rail throughout the world. All materials used in the construction will be to
withstand extremes of temperature range from -40OC (-40OF) to +70OC (+158OF) without effect
on the strength of the basic structure and watertightness.
1.3
1.3.1
1.3.2
T.I.R. Certification
All the containers will be certified and comply with "The Customs Convention on the
International Transport of Goods under the cover of T.I.R. Carnets." or "The Customs
Convention on Containers."
1.3.3
C.S.C. Certification
All the containers will be certified and comply with the requirements of the "International
Convention for the Safe Containers."
1.3.4
T.C.T. Certification
All exposed wooden components used for container will be treated to comply with the
requirements of "Cargo Containers - Quarantine Aspects and Procedures" of the Commonwealth
Department of Health, Australia.
1.3.5
U.I.C. Registration
All the containers will be registered and comply with the "International Union of Railways."
1.3.6
Classification society
All the containers will be certified for design type and individually inspected by classification
society, BV, ABS, LR, GL or CCS
* Note:
BV
ABS
LR
GL
CCS
1.4 Handling
The container will be constructed to be capable of being handled without any permanent
deformation under the following conditions:
1.5
a)
Lifting, full or empty, at top corner fittings vertically by means of spreaders fitted with
hooks, shackles or twistlocks.
b)
Lifting, full or empty, at bottom corner fittings using slings with terminal fittings at any
angles between vertical and 30 degrees to the horizontal.
Transportation
The container will be constructed to be suitable for transportation in the following modes:
a)
Marine :
b)
Road
c)
Rail
2.
2.1
External Dimensions
Length
12,192 + 0mm
-10mm
2,438 + 0mm
- 5mm
2,896 + 0mm
- 5mm
Width
Height
2.2
1)
No part of the container will protrude beyond the external dimensions mentioned above.
2)
Internal Dimensions
Length
11,978 + 0mm
-10mm
2,350 + 0mm
- 5mm
2,645 + 0mm
- 5mm
Width
Height
2.3
2.4
2,338
Height
2,535
2.5
2.6
+ 0mm
- 5mm
+ 0mm
- 5mm
2,630 cu.ft
Gooseneck tunnel
Length
Width
3,262
1,029
Height
120
mm
+3mm
-0mm
+0mm
-3mm
Ratings
Max. Gross Weight (R)
Tare Weight (design) (T)
Max. Payload (P)
30,480 kgs
4,180 kgs
26,300 kgs
67,200 lbs
9,220 lbs
57,980 lbs
3.
Materials
3.1
General
The following materials will be used in the construction of containers.
3.2
Part specification
Parts
1)
Materials
Roof panel
Door panel
Side panel
Door sill
Cross member
Gooseneck tunnel
Bottom side rail
Door header (upper & lower)
Door horizontal frame
Door vertical frame
Door sill lower (front end)
Top side rail
Corner posts (outer)
Corner posts (inner)
3)
4)
Corner Fitting
5)
6)
7)
Door gasket
EPDM
8)
Floor board
9)
Ventilator
2)
* Note:
4.
Construction
4.1
General
4.1.1
The container will be constructed with steel frames, fully vertical-corrugated steel sides and
horizontal-corrugated steel double doors at two ends, die-stamped steel roof and corner fittings.
4.1.2
All welds of exterior including the base frames will be continuous welding using CO 2 gas, but
inner part of each bottom side rail will be fastened by staggered stitch welding.
4.1.3
Interior welds - when needed - will be stitched with a minimum length of 15mm.
4.1.4
Gaps between adjacent components to be welded will not exceed 3mm or the thickness of the
parts being welded.
4.1.5
Chloroprene sealant is to be applied at periphery of floor surface and inside unwelded seams,
butyl sealant is used to caulk at invisible seam of floor joint area and between door gasket and
frame.
4.1.6
The wooden floor will be fixed to the base frames by zinc plated self-tapping screws.
4.2
Protrusion
4.2.1
The plane formed by the lower faces of the bottom side rails and some transverse members shall
be positioned by 12.5mm +5/-1.5mm above the plane formed by the lower faces of the bottom
corner fittings.
4.2.2
The top corner fittings are to protrude a minimum of 6mm above the highest point of the roof.
4.2.3
The outside faces of the corner fittings will protrude from the outside faces of the corner posts by
nominal 4mm.
4.2.4
The outside faces of the corner fittings will protrude from the outside faces of the sides by
nominal 8mm.
4.2.5
Under maximum payload, no part of the container will protrude below the plane formed by the
lower faces of the bottom corner fittings at the time of maximum deflection.
4.2.6
Under 1.8 x maximum gross weight, no part of the container will protrude more than 6.0mm
below the plane formed by the lower faces of the bottom corner fittings at the time of maximum
deflection.
4.3
Corner fittings
The corner fittings will be designed in accordance with ISO 1161 (Amd.1990) and manufactured
at the works approved by classification society.
4.4
4.4.1
4.4.2
Cross member
The cross members are made of pressed channel section steel with a dimension of
45x122x45x4.0mm and 45x172x45x4.0mm for the normal areas and 75x122x45x4.5mm for the
floor joint areas. The cross members are placed fully to withstand floor strength and welded to
each bottom side rail.
4.4.3
Gooseneck tunnel
The gooseneck tunnel consists of 4.5mm thick top plate, fourteen 4.5 mm thick pressed channel
section bows, one 4.0mm thick enclosed section tunnel rear bolster which is separated into two
"C" section parts, two 4.5mm thick built-up "L" section tunnel side rails, and twenty 4.0mm thick
tunnel outriggers.
4.5
Flooring
The floor will consist of twelve pieces plywood boards, floor center rail, and self-tapping screws.
4.5.1
Floor
The wooden floor to be constructed with 28mm thick 19-ply hardwood plywood boards are laid
longitudinally on the transverse members between the 4.0mm thick flat bar floor centre rail and
the 3.0mm thick pressed angle section steel floor guide rails stitched welded to the bottom side
rails.
The floor boards are tightly secured to each transverse member by self-tapping screws, and all
butt joint areas and peripheries of the floor boards are caulked with sealant.
1)
2)
3)
Wood species :
Glue
:
Treatment
:
a)
Preservative:
b)
4.5.2
Apitong or Keruing
Phenol-formaldehyde resin.
Self-tapping screw
Each floor board is fixed to the transverse members by zinc plated self-tapping screws that are
8.0mm dia. shank x 16mm dia. head x 45mm length, and fastened by four screws per cross
member but five screws at joint areas. Screw heads are to be countersunk with about 2mm below
the floor top surface.
4.6
4.6.1
Door sill
The door sill (without gooseneck tunnel) to be made of a 4.5mm thick pressed open section steel
is reinforced by four internal gussets at the back of each locking cam keeper location.
A 200 x 75mm section is cut out at each end of the door sill and reinforced by a 200 x 75mm
channel steel as a protection against handling equipment damages.
Other door sill (with gooseneck tunnel) consists of 4.5mm thick flat steel two vertical weds at
each end, 80x40x3.2mm thick full length square tube top rail. The door sill also has two sill
recess (slot recess) for protection damage from twist locking device. The sill recess fabricated
with channel section 200x75mm and welded to the door sill together.
4.6.2
Corner post
Each corner post of hollow section is fabricated with 6.0mm thick pressed steel outer part and
40x113x12mm thick hot rolled channel section steel inner part, which are welded continuously
together to ensure a maximum width of the door opening and to give a sufficient strength against
stacking and racking forces.
Four (4) sets of hinge pin lugs are welded to each rear corner post.
4.6.3
Door header
The door header is constructed with a 4.0mm thick pressed "U" section steel lower part having
four internal gussets at the back of each locking cam keeper location and a 3.0mm thick pressed
steel upper part, which are formed into box section by continuous welding.
4.7
Door
4.7.1
Each container will have double wing doors at a end frame, and each door will be capable of
swinging approximately 270 degrees.
4.7.2
Each door is constructed with two 3.0mm thick pressed channel section steel horizontal frames
for the top and bottom, 100x50x3.2mm rectangular hollow section vertical frames for the post
side and center side of door respectively, 2.0mm thick horizontally corrugated steel door panel,
which are continuously welded within frames.
4.7.3
Two sets of galvanized locking assemblies which is the same model with "BE-2566 Modified"
with steel handles are fitted to each door using high tensile zinc plated steel bolts according to
TIR requirements. Locking bar retainers are fitted with nylon bushings at the top, bottom and
intermediate bracket.
Locking gears should be assembled after painting and not to be painted.
4.7.4
The left hand door can not be opened without opening the right hand door when the container is
sealed in accordance with TIR requirements.
4.7.5
The door hold-back of nylon rope is provided to the centre locking bar on each door and a hook
of steel bar is welded to each bottom side rail.
4.7.6
Each door is suspended by four hinges being provided with stainless steel pins, self-lubricating
nylon bushings and brass washers, which are placed at the hinge lugs of the corner posts.
4.7.7
The door gasket to be made of an extruded triple lip type (J-type) EPDM rubber is installed to the
door peripheral frames with stainless steel gasket retainers and fastened by stainless steel blind
rivets at a pitch of 150mm.The door gasket must be caulked with butyl sealant before installation
to the door frames.
4.8
Roof structure
The roof will be constructed with eleven five-corrugated (die-stamped) steel panels and four
corner protection plates.
4.8.1
Roof panel
The roof panel is constructed with 2.0mm thick die-stamped steel sheets having about 6.0mm
upward smooth camber, which are welded together to form one panel and continuously welded to
the top side rails and top end rails. All overlapped joints of inside unwelded seams are caulked
with chloroprene sealant.
4.8.2
Protection plate
Each corner of the roof in the vicinity of top corner fitting is reinforced by 3.0mm thick
rectangular steel plate to prevent the damage caused by mishandling of lifting equipment.
4.9
4.10
Side wall
The trapezium section side wall is constructed with 1.6mm thick fully vertically continuouscorrugated steel panels at the intermidiate area and 2.0mm thick fully vertically continuouscorrugated steel panels at both ends which are butt welded together to form one panel and
continuously welded to the side rails and corner posts. All overlapped joints of inside are caulked
with chloroprene sealant.
4.11
Special feature
10
5.
Surface preservation
5.1
Surface preparation
1)
2)
3)
All steel surfaces - prior to forming or after - will be fully abrasive shot blasted
conforming to Swedish Standard SA2 1/2 to remove all rust, dirt, mill scale and all other
foreign materials.
All door hardware will be hot-dipping zinc galvanized with approximately 75 microns
thickness.
All fasteners such as self-tapping screws and bolts, nuts, hinges, cam keepers and
lashing fittings will be electro-galvanized with approximately 13 microns thickness.
5.2
Primer coating
5.2.1
Prior to assembly
All steel surfaces will be coated with 10-15 microns thick two-pack polyamide cured zinc rich
epoxy primer immediately after shot blasting, and then dried up in drying room.
5.2.2
After assembly
1)
2)
5.3
Top coating
1)
2)
5.4
All weldments will be shot blasted to remove all welding fluxes, spatters, burnt primer
coatings caused by welding heat, and other foreign materials.
Then all blasted weldments will be coated with zinc rich epoxy primer.
Exterior of assembled container will be coated again 10 microns with zinc rich epoxy
primer and again 35-40 microns epoxy primer prior to top coating.
After drying of primer, exterior of container will be coated again with high build
chlorinated rubber paint and interior will be coated again with polyamide cured epoxy
resin based high build coating.
The dry film thickness of top coating will be 55-60 microns for the exterior and 50
microns for the interior.
Under coating
After completion of flooring, all the understructures and floor will be coated with 230 microns
dry film thickness bituminous coating.
5.5
INT.
20-25
BASE
20-25
50
55-60
110
120
11
70
230
250
6.
Marking
6.1
Arrangement
The container will be marked in accordance with ISO, TCT, CSC, UIC and TIR requirements,
owner's marking specifications and other required regulations.
6.2
Materials
1) Decal :
Self-adhesive, high tensile PVC film for seven (7) years guarantee
without peeling off, tenting or colour fading.
2)Certification plate:
18-8 type stainless steel plates to be chemically etched by acid and
treated by enamel.
6.3
Specifications
1)
Identification plates such as consolidated data plate consisting of CSC, TIR and TCT
will be rivetted on the door permanently by stainless steel blind rivets. The entire
periphery except underside will be caulked with silicone sealant.
2)
The owner's serial numbers and manufacturer's serial numbers will be stamped into the
top plane of lower left corner fittings.
12
7.
7.1
Testing
7.1.1
Prototype testing
The prototype container manufactured in accordance with this specification will be tested by
manufacturer under the supervision of classification society.
Test methods
A)
Stacking
Internal load : 1.8R-T
Test load : 86,400kg/post.
B)
Lifting vertically.
Time duration : 5 minutes
C)
D)
Restraint (longitudinal)
Internal load : R-T
Test load : 2R
E)
Floor strength
Test load : 5,460 kgs
(12,040 lbs)
F)
G)
H)
I)
Racking (transverse)
Test load : 15,240 kgs
J)
Racking (longitudinal)
Test load : 7,620 kgs
K)
Operation of door
L)
M)
Weatherproofness
8.
Guarantee
8.1
Structure
R
T
P
All the containers shall be guaranteed by manufacturer to be free from defects in materials,
workmanship and structure for a period of one (1) year from the date of acceptance of the
container by the buyer.
8.2
Painting
8.2.1
The paint system coated on the container surface shall be guaranteed to be free from corrosion
and failure for a period of five (5) years from the date of acceptance of the container by the buyer.
8.2.2
Corrosion is defined as rusting which exceeds RE3 (European Scale of degree of Rusting) on at
least ten (10) percent of the total container surface, excluding that resulting from impact or
abrasion damage, contact with solvents or corrosive chemicals and abnormal use.
8.2.3
If the corrosion exceeds RE3 as defined above within the guarantee period, inspection of the
corrosion shall be carried out by the buyer, the factory and paint manufacturer to detect the
cause.
As the result of the inspection, if it is mutually agreed and accepted that the corrosion has been
caused by the defective paint quality and/or poor workmanship, the fctory and/or paint
manufacturer shall correct the defect on their accounts.
8.3
Decals
Decals applied on the container shall be guaranteed for a period of seven (7) years without
peeling off, tenting or colour fading if decals are supplied by the factory.
14