Standard ISO Container

Inspection & Repair Guidelines

February 2019
(updates marked in yellow)

CONTENTS

1. Scope

2. Introduction

3. Main Structural Components

4. Other Components

5. Other Items
1 SCOPE

This “Hapag-Lloyd Standard ISO Container Repair and Inspection Guidelines” is

based on the UCIRC (Unified Container Inspection and Repair Criteria) as well as
additional Instructions generated from know-how and experience during the
past decades of Container operation.

The purpose of these Guidelines is to assist Hapag-Lloyd M&R Inspectors to evaluate

which damages to a Container under Hapag-Lloyd’s custody require repair and which
damages are to be considered “acceptable” and as such does NOT require repair.
Furthermore these guidelines will recommend repair methods for individual
damages indicated. In case not further specified repairs shall be performed
according to the “IICL Repair Manual“ (latest version).

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.

2 INTRODUCTION

2.1 GENERAL

• These criteria are designed for use at all container inspections;

• 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 safety 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.

• Materials of the same quality and dimensions as the original

materials must be used for any repairs.
2.2 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 and ISO +5mm on the end faces;

• Previous repairs should not be reworked unless the structural integrity

of the container is compromised or it is unsuitable for cargo.

2.3 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 dimension by more than 50mm

• The container is unsuitable for cargo;

• Cracks in welds unless otherwise stated are present;

• Corrosion causing loss of structural integrity is present.

• A condition causing loss of watertightness or thermal tightness is

present

• Corner Castings are cracked or deformed

2.4 WEAR & TEAR

This is defined as unavoidable change or deterioration of the condition of

the container brought about by routine operational use and includes:

• General paint deterioration;

• Corrosion

• Deterioration of door gaskets and fittings;

• Deterioration of door fixings arising from deterioration of doors

• Which is not affecting the water tightness

2.6 MANUFACTURING DEFECTS

Manufacturing defects or suspected manufacturing defects must be reported
to the container Owner without delay.
2.7 GLOSSARY OF TERMS

Bent/Bowed
Deflection in a component that causes a permanent change in the original
geometry of the component over some portion of its length or width.

Broken
Fractured or shattered into two or more separate pieces.

Cracked
Having a fracture which penetrates the entire thickness of the material
and causes it to split.

NB: If a weld between two different metal components has any separation in
it, even if the entire thickness of the weld material is not involved, that weld
must be considered to be ‘cracked’.

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

Delamination
Separation of any component in a "sandwich construction" from the
underlying component.

Dent
A localised depression in a component made by pressure, impact or a blow
that causes a change in shape over a limited area of the component.

Holed
Perforated through the entire thickness of material.

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

Flange
The projecting rim or edge on a component such as a bottom side rail,
cross member etc

Web
The material adjoining a flange
3 MAIN STRUCTURAL COMPONENTS
COMPONENT DAMAGE RECOMMENDED
REPAIR METHODS

3.1 RAILS, HEADERS & SILLS

Top side rail * Holed, cut, torn, Weld or straighten, or

broken, cracked straighten and weld, or
insert, or section, or
* Deformation in excess of renew
30mm

Bottom side rail Weld or straighten, or

– web * Holed, cut, torn, straighten and weld, or
broken, cracked insert, or section, or
renew
*Deformation in excess
of 50mm

- Flange * Cracks or tears which Weld or straighten

extend into web radius and weld

Front & rear headers * Holed, cut, torn, Weld or straighten, or

broken, cracked straighten and weld, or
insert, or section, or
* Deformation in excess of renew
40mm

Front & rear sill * Holes, cut, torn, broken, Weld or straighten, or
cracked straighten and weld, or
insert, or section, or
* Deformation exceeding 50mm renew

3.2 POSTS
Corner posts * Holed, cut, torn, broken, Weld, or straighten and
cracked weld, or insert or renew
Straighten, or insert or
renew

* Dents exceeding 20mm

* Bend, bow or deformation, if

exceeding outer faces of corner
castings by +5mm on end face
or +10 mm on side face

Corner castings * Cracked, deformed, broken Replace

(as per IICL TB 015) * Deformation preventing Replace

correct twistlock operation
3.3
FLOOR UNDERSTRUCTURE

Fork lift pocket & * Top plate separation from Straighten or weld, or
goose neck floor in excess of 10mm or straighten and weld,
tunnel assembly floor screws ineffective or insert, or renew

* Web holed, cut, torn, or Weld, or straighten and

cracked in excess of 500mm weld, or insert, or
or extending into a weld renew
connection

* Lower flange connection Weld, or straighten and

to bottom side rail, holed, weld, or insert, or
cut, torn, cracked extending section or renew
into web radius

* Web deformation below Straighten, or

line of corner castings straighten and weld,
or insert, or renew

* Top plate pushed up in excess Straighten or weld, or

of 50mm, cut, torn or broken straighten and weld,
or insert, or renew

* Strap broken, cracked, Weld, or straighten and

cut, torn, missing weld, or replace

Cross members * Web holed, torn, broken, Weld, or straighten and

cracked, cut, missing weld, or insert, or
renew

* Web deformed in excess Straighten, or renew

of 75mm

* Web upper flange separated Straighten and refix,

from floor by more than 10mm or renew

* Bowed up by more than Straighten, or renew

50mm or below line of
corner castings
4 OTHER COMPONENTS
COMPONENT DAMAGE RECOMMENDED
REPAIR METHODS

4.1 FLOOR
Floor planks and * Gouge greater than 15mm Section or renew
panels deep irrespective of length

* Gouge more than 6mm deep Section or renew

and greater than 150mm wide
irrespective of length

* Delamination or other Replace if structural

damage (affecting floor
strength)

* Difference in height between Refasten

adjacent
planks / panels greater than
10mm
Plug (maximum 25mm
* Holes other than nail holes diam.)

Floor fastenings * Protruding Refasten

* Three or more adjacent Refasten or replace

broken / loose, missing
Fasteners

Steelfloor * Dents into the cube which Straighten, or straighten

prevent proper cargo stowage and weld or insert
and/or securing

* Downward dents exceeding Straighten, or straighten

25 mm and weld or insert

* Holed, torn or cut Weld, or straighten and

weld or insert
4.2 DOORS

Door * Holed, cut, torn, broken, Weld or straighten, or

cracked component or weld, or straighten and weld, or
deformation affecting security patch, or insert, or
and operation of doors renew

* Missing / broken or loose Replace or refix

parts which affect door
operation or watertightness

J Bars * If interfering with door Weld or straighten, or

operation straighten and weld, or
insert
Data plates * Loose or missing plates Refasten or replace

4.3 PANELS
Side / front /roof * Dents into cube which reduce Straighten, or
panels including the internal width by more than straighten and weld,
header plate 50mm from the inner patch, insert or renew
corrugation including multiple
dents, or 70mm from the floor
to the roof inner corrugation
Weld, or straighten and
* Holed, torn or cut weld, patch, or insert

Straighten, or
* Dents exceeding the outer straighten and weld, or
face of corner castings + 40mm patch, or insert

5 OTHER ITEMS
COMPONENT DAMAGE RECOMMENDED
REPAIR METHODS

Lashing rings * Broken, cracked or missing or Weld, or replace, or

non functional straighten

Surfaces * Glue (Sticky) Clean and/or paint

* Odour, infestation, debris, Clean and/or remove

contamination that can be
transferred

* Vents blocked, loose, Repair/replace

damaged and not weathertight,
missing
* Graffiti / foreign markings Repair / remove
- offensive / possibly offensive

ISO decals * Missing or illegible Replace

Rain gutters * Damage affecting door Straighten or remove

operation or exceeding outer
face of corner castings +10mm

Hazardous labels * Remaining on panels Remove