CENTRE EQUIPMENT & EMR

STANDARD TIME SYSTEM MANUAL

STEEL DRY CONTAINERS

(Mode 03)
Centre Equipment & EMR STS Manual – Steel Dry Containers

Contents

1 SCOPE............................................................................................................................................................................. 4

1.1 THE PURPOSE OF THIS MANUAL ............................................................................................................................................. 4

2 GENERAL REMARKS ........................................................................................................................................................ 4

2.1 GLOSSARY OF REPAIR TERMS ................................................................................................................................................. 5

2.2 CALCULATION OF PATCH SIZES ............................................................................................................................................... 5
2.3 HOW TO READ THE TABLES ................................................................................................................................................... 6

3 REPAIR CODES ................................................................................................................................................................ 6

3.1 MISCELLANEOUS ................................................................................................................................................................. 6

3.1.1 Preparation times ................................................................................................................................................... 6
3.1.2 Cleaning-related ..................................................................................................................................................... 6
3.1.3 Decals and ISO marking .......................................................................................................................................... 7
3.1.4 Codes for 45ft. containers only ............................................................................................................................... 8
3.1.5 Others ..................................................................................................................................................................... 8
3.2 ROOF ASSEMBLY ................................................................................................................................................................. 9
3.2.1 Roof panel replacement ......................................................................................................................................... 9
3.2.2 Roof patching / straightening................................................................................................................................. 9
3.3 FRONT ASSEMBLY ................................................................................................................................................................ 9
3.3.1 Front panel replacement ........................................................................................................................................ 9
3.3.2 Front panel patching / straightening.................................................................................................................... 10
3.3.3 Front header replacement .................................................................................................................................... 10
3.3.4 Front header inserting / strainghtening ............................................................................................................... 10
3.3.5 Front sill replacement ........................................................................................................................................... 11
3.3.6 Front sill inserting / strainghtening / welding ...................................................................................................... 11
3.3.7 Front corner post replacement ............................................................................................................................. 12
3.3.8 Front corner post inserting / straightening .......................................................................................................... 12
3.3.9 Front frame – others ............................................................................................................................................. 12
3.4 SIDE ASSEMBLY ................................................................................................................................................................. 13
3.4.1 Side panel replacement ........................................................................................................................................ 13
3.4.2 Side panel inserting / straightening...................................................................................................................... 13
3.4.3 Top side rail replacement ..................................................................................................................................... 14
3.4.4 Top side rail inserting / straightening................................................................................................................... 14
3.4.5 Top side rail sectioning ......................................................................................................................................... 14
3.4.6 Hanger rail sectioning and replacement .............................................................................................................. 15
3.4.7 Bottom side rail replacement ............................................................................................................................... 15
3.4.8 Bottom side rail inserting / straightening............................................................................................................. 15
3.4.9 Bottom side rail sectioning ................................................................................................................................... 16
3.4.10 Side assembly – others ......................................................................................................................................... 16
3.5 REAR ASSEMBLY ................................................................................................................................................................ 16
3.5.1 Rear header replacement ..................................................................................................................................... 16
3.5.2 Rear header inserting / strainghtening ................................................................................................................ 17
3.5.3 Rear sill replacement ............................................................................................................................................ 17
3.5.4 Rear sill inserting / strainghtening / welding ....................................................................................................... 17
3.5.5 Rear corner post replacement .............................................................................................................................. 18
3.5.6 Rear corner post inserting / straightening ........................................................................................................... 18

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3.5.7 Rear frame – others .............................................................................................................................................. 19

3.6 DOOR ASSEMBLY............................................................................................................................................................... 19
3.6.1 Door panel replacement ....................................................................................................................................... 19
3.6.2 Door panel patching / straightening .................................................................................................................... 19
3.6.3 Door frame ........................................................................................................................................................... 20
3.6.4 Door Gasket .......................................................................................................................................................... 20
3.6.5 Door hardware replacement / repair ................................................................................................................... 21
3.6.6 Door hardware straightening ............................................................................................................................... 21
3.6.7 Door – MiScellaneous ........................................................................................................................................... 21
3.7 FLOORS ........................................................................................................................................................................... 22
3.7.1 Floor repairs.......................................................................................................................................................... 22
3.7.2 Floor planks / WPC Floor ...................................................................................................................................... 23
3.7.3 Playwood floor repairs .......................................................................................................................................... 23
3.7.4 Center rail repair................................................................................................................................................... 24
3.8 UNDER-STRUCTURE ASSEMBLY ............................................................................................................................................ 24
3.8.1 Cross members ..................................................................................................................................................... 24
3.8.2 Gooseneck tunnel ................................................................................................................................................. 24
3.8.3 Forklift pocket ....................................................................................................................................................... 25

4 APPENDICES ................................................................................................................................................................. 26

4.1 APPENDIX 1 – TB003 – FINGER CRACKS IN FLOORBOARDS ....................................................................................................... 26

4.2 APPENDIX 2 – REVISED CROSS MEMBER REPAIR CRITERIA......................................................................................................... 27

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Centre Equipment & EMR STS Manual – Steel Dry Containers

1 SCOPE
1.1 The Purpose of this Manual
This manual has been prepared with the intention to inform about the use of Standard Time System
Codes (hereafter STS Codes) for box repairs on containers (Mode 03).

If there are any required repairs but not described herein, or any clarification to the document,
please contact Maersk Line EMR Team in your location or eventually "Centre Equipment & EMR" in
Copenhagen.

2 GENERAL REMARKS
Unless mentioned otherwise, all estimations of man hours are based on high-cube containers and
they are including:
- MIG welding, when there is joining of steel parts.
- 3-coat paint system according to Maersk Line prescribed colors and film thicknesses.

The use of spare parts (e.g. corner casting, corner posts, cross members, etc.), shall be delivered in
the correct sizes whenever estimation has any spare parts. Dimensions of Maersk Line parts are
available in the container General Arrangement Drawing. Please ask your local Maersk Line contact
to obtain more details, if required.

Time of manufacturing of spare parts shall be included in the spare parts’ price.

Unless mentioned otherwise, the steel used for container repair shall be CORTEN-A steel (SPA-H)
with Yield Point = 350 N/mm2 and Tensile Strength = 490 N/mm2

Figure 1 - General assembly

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2.1 Glossary of Repair Terms

Term Description
Replace Remove the damaged part(s) and install new one(s) instead
Reinstall Remove a sound part, due to a near repair for example, and then in-
stall the same part again in its original position.
Insert A part from a structure (such as top rail, post, etc.) or panel, which
is replaced with a part from the same material and exact size, fixed
with butt-welding to the surrounding structure. The part is covering
only two faces of the structure’s cross section.
Patch A part from a panel (such as roof panel etc.) that is replaced with a
part from the same material and slightly bigger size, fixed with weld-
ing to the surrounding structure.
Section A part from a structure (such as top rail) that is replaced with anoth-
er part from the same material and exact size; fixed with butt-
welding to the surrounding structure. The part is covering the whole
section of the structure.
Straighten Return the affected part to its original profile by means of hydraulic
jacks or similar. No material is used for such repair method.

2.2 Calculation of Patch Sizes

If the exact patch size is not mentioned in this manual, please use the repair code with dimensions
that covers the circumference of the actual patch to be used.

E.g. If the required roof patch is 850x450 (perimeter =

2,600 mm). The proper code to use is 1117 (600x854)
cause the related perimeter is 2,908 mm which covers
the required size.

E.g. If the required roof patch is 1,150x500 (perimeter

= 3,300 mm). The proper code to use is 1118
(900x1,060)  Perimeter = 3,920 mm.

It is expected that repairers prepare and stock frequently used size patch sizes. It is further ex-
pected that patches are not tailor made but that the nearest size corresponding to the dimensions of
the damage area is chosen for repair.

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2.3 How to Read the Tables

STS Code as Code description as in Maximum Whether material

mentioned in Merc+ and related pieces per is allowed for
Merc+ comments if applicable Size of repair in code. repair
on how and when to use mm if applicable
the code (patch 300x300) or
(insert 150) It shows whether
Time allowed
preparation time
per piece
will be counted for
this code.

3 REPAIR CODES
3.1 Miscellaneous
3.1.1 PREPARATION TIMES
STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
0003 Preparation - For total repair time less than --
1 0.1 N N
or equal to 2 hrs.
0005 Preparation - For total repair time between 2 --
1 0.2 N N
& 8 hrs.
0008 Preparation - For total repair time between 8 --
1 0.3 N N
& 24 hrs.
0011 Preparation - For total repair time between --
1 0.5 N N
24 & 40 hrs.
0014 Preparation - For total repair time exceeding --
1 0.8 N N
40 hrs.

3.1.2 CLEANING-RELATED
STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
Container - Mechanical Cleaning
0919 NOTE: REQUIRES SPECIAL APPROVAL FROM -- 2 1 Y N
MAERSK EMR OFFICE
Container - Cleaning - Internal ordinary
0913 -- 1 0.1 N N
sweeping or air-blowing (20ft. DC)
Container - Cleaning - Internal ordinary
0914 -- 1 0.2 N N
sweeping or air-blowing (40ft. DC)
0920 Container - Excessive 10ft. Spot Cleaning -- 1 0 Y N
0912 Container - Excessive 20ft. Spot Cleaning -- 1 0 Y N
0921 Container - Excessive 30ft. Spot Cleaning -- 1 0 Y N

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0915 Container - Excessive 40ft. Spot Cleaning -- 1 0 Y N

Container - Food Upgrade (20'DC) - G1 High
0910 -- 1 0 Y N
Complexity/Effort
Container - Food Upgrade (20'DC) - G2
0922 -- 1 0 Y N
Standard Complexity/Effort
Container - Food Upgrade (20'DC) - G3 Low
0923 -- 1 0 Y N
Complexity/Effort
Container - Food Upgrade (40'DC) - G1 High
0911 -- 1 0 Y N
Complexity/Effort
Container - Food Upgrade (40'DC) - G2
0924 -- 1 0 Y N
Standard Complexity/Effort
Container - Food Upgrade (40'DC) - G3 Low
0925 -- 1 0 Y N
Complexity/Effort
Container - Partial blast and re-paint (RE-
0918 QUIRES SPECIAL APPROVAL FROM MAERSK -- 2 2 Y N
EMR)
General - Remove cargo labels
0986 -- 9 0.1 N N
NOTE: TWO CARGO LABELS PER PIECE
0806 General - Remove nails -- 1 0.1 N N

As a rule of thumb, cleaning is NOT required for each

container. If it’s necessary to clean, use STS Codes for
ORDINARY INTERNAL CLEANING (SWEEP / AIR BLOW)
(20’ / 40’ DC). If part of the container requires exces-
sive cleaning, use the codes in this section.

Please Use Water Considerately

Water cleaning is harmful to the environment and as
well harmful to the wooden floorboards.

3.1.3 DECALS AND ISO MARKING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
0953 Decals - Replace - Container check digit -- 7 0.1 Y N
Decals - Replace - Miscellaneous marking
NOTE: THIS CAN INCLUDE WEIGHT DECALS
0959 -- 4 0.2 Y N
ON DOOR, HEAVY LOAD STICKER, HEIGHT
STICKER, ETC.
Decals - Replace - One complete container
0956 ID -- 6 0.4 Y N
NOTE: PREFIX + 6 DIGITS + CHECK DIGIT
0954 Decals - Replace - UIC decal -- 2 0.1 Y N
Decals - Replace - Up to four letters (prefix)
0951 -- 7 0.1 Y N
NOTE: E.G. MRKU
Decals - Replace - Up to three digits
0952 -- 9 0.1 Y N
(number)

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If Maersk Logo on container door is damaged or miss-

ing, DO NOT repair or replace.

Replace other Owners logos ONLY IF repair to the area

is also required

3.1.4 CODES FOR 45FT. CONTAINERS ONLY

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
45ft. Only - 1st Intermediate Header - Re-
4422 -- 1 2.9 Y Y
place
45ft. Only - 2nd Intermediate Header - Re-
4423 -- 1 2.6 Y Y
place
45ft. Only - Front Header - Replace 1st in-
2422 -- 1 2.9 Y Y
termediate header
45ft. Only - Front Header - Replace 2nd in-
2423 -- 1 2.6 Y Y
termediate header
45ft. Only - Intermediate Front Post - Re-
2623 -- 2 4.8 Y Y
place
4623 45ft. Only - Rear Corner Post – Replace -- 2 4.8 Y Y
NOTES:
- Whenever applicable, codes include support of the roof/floor while replacing the parts.
- For the headers, time includes removing the damaged part, installing the new part, weld-
ing and painting of the new part (primer + top coat), and fabrication and installation of
corner protection plates.
- For corner posts, time includes reinstallation of surrounding floorboards, includes installa-
tion of lashing bars, but excluding any corner casting replacement.

3.1.5 OTHERS
STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
Container - Check ISO dimensions
9200 -- 4 0.3 N Y
(3 measurements)
General - CSC Inspection – only for non-
0909 -- 1 0.1 N N
ACEP scheme containers
General - Emergency repair
0802 NOTE: USE ONLOY FOR FULL DRY CONTAIN- -- 3 0.5 Y N
ERS
0917 General - Handling & trucking charges -- 2 0 N N
0975 General - Import tax -- 1 0 N N
0985 General - Re-install data plate -- 1 0.2 N N
General - Repair cost for non-STS repair
0950 -- 1 10 Y N
shop
General - Replace missing rivets or huckbolts
0804 -- 7 0.1 Y N
NOTE: 1 PC. = UP TO 6 RIVETS
0977 General - Sales tax for labour -- 1 0 Y N
0976 General - Sales tax for parts -- 1 0 Y N

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0979 General - VAT for labour -- 1 0 Y N

0978 General - VAT for parts -- 1 0 Y N
7920 Any Gusset Plate - Replace -- 4 0.4 Y Y
7981 Any Gusset Plate - Straighten -- 4 0.1 N Y
7982 Any Gusset Plate - Straighten & Re-weld -- 4 0.2 N Y
Any Panel - Straighten, Re-weld & Paint Cuts
7892 >500 9 0.3 N Y
and/or Cracks - Bigger than 500mm length
Any Panel - Straighten, Re-weld & Paint Cuts
7891 <500 9 0.2 N Y
and/or Cracks - Less than 500mm length

3.2 Roof Assembly

3.2.1 ROOF PANEL REPLACEMENT
STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
Roof Panel – Replace First Panel (attached to 1050x2360
1121 2 4.7 Y Y
header) – 1050x2360x2.0 mm T=2.0
Roof Panel – Replace Intermediate Panel – 1050x2360
1122 9 2 Y Y
1050x2360x1.6 mm T=1.6

3.2.2 ROOF PATCHING / STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
1111 Roof Panel - Patch 150x212 8 0.8 Y Y
1112 Roof Panel - Patch 150x318 9 0.8 Y Y
1113 Roof Panel - Patch 200x424 9 1 Y Y
1114 Roof Panel - Patch 200x638 9 1 Y Y
1115 Roof Panel - Patch 300x638 9 1.3 Y Y
1116 Roof Panel - Patch 450x746 9 1.5 Y Y
1117 Roof Panel - Patch 600x854 5 1.8 Y Y
1118 Roof Panel - Patch 900x1050 5 2.2 Y Y
1119 Roof Panel - Patch 1200x1050 5 2.4 Y Y
Up to
1181 Roof Panel – Straighten 9 0.2 N Y
1000x1000
NOTES:
- Times in codes 1111-1119 include welding and painting (primer + top coat).
- For roof first panel (adjacent to headers), thickness shall be 2.0mm.
- For roof intermediate panels, thickness shall be 1.6mm.
- Panel straightening shall be performed by means of hydraulic tools.

3.3 Front Assembly

3.3.1 FRONT PANEL REPLACEMENT
STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
Front Panel – Replace 1019x2300
2122 2 3.8 Y Y
NOTE: USE FOR 20FT. & 40FT. 8’6’’ ONLY T= 2.0
2121 Front Panel – Replace 1019x2600 2 4.2 Y Y

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NOTE: USE FOR 40FT. 9’6’’ & 45FT. ONLY T= 2.0

NOTES:
- Time includes removing the damaged part, installing the new part, and welding and paint-
ing (primer + top coat).
- Front panel thickness shall be 2.0mm.

3.3.2 FRONT PANEL PATCHING / STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
2111 Front Panel - Patch 100x150 6 0.7 Y Y
2112 Front Panel - Patch 150x300 6 0.9 Y Y
2113 Front Panel - Patch 200x300 4 0.9 Y Y
2114 Front Panel - Patch 200x450 4 1.1 Y Y
2115 Front Panel - Patch 300x600 4 1.4 Y Y
2116 Front Panel - Patch 450x750 3 1.7 Y Y
2117 Front Panel - Patch 600x900 2 2 Y Y
2118 Front Panel - Patch 900x1028 2 2.4 Y Y
2119 Front Panel - Patch 1200x1028 2 2.6 Y Y
Up to
2181 Front Panel - Straighten 2 0.3 N Y
1000x1000
NOTES:
- Times in codes 2111-2119 include welding and painting.
- Front panel thickness shall be 2.0mm.
- Panel straightening shall be performed by means of hydraulic tools.

3.3.3 FRONT HEADER REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
2421 Front Header - Replace complete header -- 1 3.4 Y Y
NOTES:
- Time includes removing the damaged part, installing the new part, welding and painting of
the new part (primer + top coat), and fabrication and installation of corner protection
plates.
- Front header thickness should be 4.0mm.

3.3.4 FRONT HEADER INSERTING / STRAINGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
2441 Front Header - Insert 150 2 0.9 Y Y
2442 Front Header - Insert 300 2 1 Y Y
2443 Front Header - Insert 450 2 1.1 Y Y
2444 Front Header - Insert 600 2 1.3 Y Y
2445 Front Header - Insert 900 1 1.5 Y Y
2446 Front Header - Insert 1200 1 1.7 Y Y
2447 Front Header - Insert 1500 1 1.9 Y Y
2448 Front Header - Insert 1800 1 2.2 Y Y
2481 Front Header - Straighten Any 1 0.5 N Y

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NOTES:
- Times in codes 2441-2448 include welding and painting (primer + top coat).
- Front header thickness shall be 4.0mm.
- Inserting is including corner protection plates (extension plates) and gusset plates.

Sectioning of Headers and Sills is not allowed.

3.3.5 FRONT SILL REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
2523 Front Sill - Replace complete sill (20ft.) -- 1 3.8 Y Y
2522 Front Sill - Replace complete sill (40ft.) -- 1 4.4 Y Y
NOTES:
- Time includes removing the damaged part, installing the new part, welding and painting
(primer + top coat), and removal and re-installation of surrounding floor panels.
- Front sill thickness shall be 4.0mm for 20ft. containers, and 3.0mm for 40ft. containers.

3.3.6 FRONT SILL INSERTING / STRAINGHTENING / WELDING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
2542 Front Sill - Insert 300 2 1 Y Y
2543 Front Sill - Insert 450 2 1.1 Y Y
2544 Front Sill - Insert 600 1 1.3 Y Y
2545 Front Sill - Insert 900 1 1.5 Y Y
2546 Front Sill - Insert 1200 1 1.7 Y Y
2547 Front Sill - Insert 1500 1 1.9 Y Y
2548 Front Sill - Insert 1800 1 2.2 Y Y
Front Sill - Straighten & Re-weld
2582 Any 2 0.2 N Y
NOTE: Applied to Flange Only
Front Sill – Straighten
2581 Any 2 0.1 N Y
NOTE: Applied to Flange Only
Front Sill - Insert – Twist-lock protection Up to
2541 2 0.7 Y Y
cone 300 mm
2561 Sill Reinforcement (Gusset) Plate - Replace -- 2 0.4 Y Y

NOTES:
- Times in codes 2542-2548 and 2541 include welding and painting (primer + top coat).
- Front sill thickness shall be 4.0mm for 20ft. containers, and 3.0mm for 40ft. containers.

Sectioning of Headers and Sills is not allowed.

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3.3.7 FRONT CORNER POST REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
2621 Front Corner Post – Replace (8' 6'' High) -- 2 6 Y Y
2622 Front Corner Post – Replace (9' 6'' High) -- 2 6.2 Y Y
NOTES:
- Time includes removing the damaged part, installing the new part, welding and painting
(primer + top coat), and removal and re-installation of surrounding floor panels.
- Times include also removal and installation of lashing bars.
- Codes are excluding corner casting replacement; if applicable
- Front corner post thickness shall be 6.0mm

3.3.8 FRONT CORNER POST INSERTING / STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
2641 Front Corner Post – Insert 150 2 1 Y Y
2642 Front Corner Post – Insert 300 2 1.1 Y Y
2643 Front Corner Post – Insert 450 2 1.2 Y Y
2644 Front Corner Post – Insert 600 2 1.3 Y Y
2645 Front Corner Post – Insert 900 2 1.6 Y Y
2646 Front Corner Post – Insert 1200 2 1.8 Y Y
2647 Front Corner Post – Insert 1500 2 2.1 Y Y
2681 Front Corner Post – Straighten Any 2 1.5 N Y

NOTES:
- Times in codes 2641-2647 include welding and painting (primer + top coat).
- Front corner post thickness shall be 6.0mm

Sectioning of Corner Posts is not allowed.

3.3.9 FRONT FRAME – OTHERS

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
2722 Corner Casting - Replace - Bottom Front -- 2 2.3 Y Y
2721 Corner Casting - Replace – Top Front -- 2 1.5 Y Y
2281 Front Frame - Align frame to ISO standards -- 1 0.5 N Y

NOTES:
- Times in codes 2721 and 2722 include welding and painting (primer + top coat), and re-
moval and re-installation of floor boards when applicable.

1 Repair of corner castings is not allowed. Only

replacement is allowed.
2 Corner Casting dimensions should be in accordance
to ISO 1161.

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3.4 Side Assembly

3.4.1 SIDE PANEL REPLACEMENT
STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
Side Panel - Replace - First panel 1116x2300
3221 2 3 Y Y
(8'6'' High) T= 2.0
Side Panel - Replace - First Panel 1116x2600
3121 2 3.2 Y Y
(9'6'' High) T= 2.0
Side Panel - Replace - Intermediate Panel 1116x2300
3222 9 1.7 Y Y
(8'6'' High) T= 1.6
Side Panel - Replace - Intermediate Panel 1116x2600
3122 9 1.9 Y Y
(9'6'' High) T= 1.6
Side Panel - Replace - Middle panel
556x2300
3224 (8'6'' High) 2 1.2 Y Y
T= 1.6
NOTE: for 40 & 45ft containers only
Side Panel - Replace - Middle panel
556x2600
3223 (9'6'' High) 2 1.4 Y Y
T= 1.6
NOTE: for 40 & 45ft containers only
Ventilation Holes - Drill (9 holes)
3921 NOTE: Use with connection to side panel re- -- 2 0.2 N Y
placement only.
NOTES:
- First Panel: Side Panel welded to the corner post. Or also the first panel to be replaced.
- Intermediate Panel: Side Panel adjacent to the first panel.
- Middle Panel: Side panel in the middle of the side wall assembly in 40ft. and 45ft. contain-
ers.
- Time includes removing the damaged part, installing the new part, welding and painting
(primer + top coat).

3.4.2 SIDE PANEL INSERTING / STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
3111 Side Panel - Insert 150x150 10 0.7 Y Y
3112 Side Panel - Insert 300x150 9 0.8 Y Y
3113 Side Panel - Insert 450x200 9 1 Y Y
3114 Side Panel - Insert 600x300 9 1.3 Y Y
3115 Side Panel - Insert 700x450 9 1.5 Y Y
3116 Side Panel - Insert 850x600 6 1.8 Y Y
3117 Side Panel - Insert 1000x900 5 2.2 Y Y
3118 Side Panel - Insert 1150x1200 5 2.6 Y Y
3119 Side Panel - Insert 1400x1500 4 3.1 Y Y
>500x500 &
3181 Side Panel - Straighten 9 0.2 N Y
<1000x1000
3183 Side Panel - Straighten < 500x500 9 0.1 N Y

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NOTES:
- Times in codes 3111-3119 include welding and painting (primer + top coat).
- Side panel thickness shall be 2.0mm for the corner panels (welded to corner post) and
1.6mm for all intermediate panels.

3.4.3 TOP SIDE RAIL REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
3421 Top Side Rail - Replace (20ft. Container) -- 2 7.8 Y Y
3422 Top Side Rail - Replace (40ft. Container) -- 2 15.6 Y Y
NOTES:
- Time includes removing the damaged part, installing the new part, welding and painting
(primer + top coat) as well as supporting the roof while replacement.
- Codes exclude times for replacing/re-installing the lashing rings and hanger rails. Please
use the appropriate codes; if to be replaced in connection with this repair.
- Top side rail thickness is 3.0mm.

3.4.4 TOP SIDE RAIL INSERTING / STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
3441 Top Side Rail - Insert 150 4 0.7 Y Y
3442 Top Side Rail - Insert 300 4 0.8 Y Y
3443 Top Side Rail - Insert 450 4 0.9 Y Y
3444 Top Side Rail - Insert 600 4 1 Y Y
3445 Top Side Rail - Insert 900 4 1.1 Y Y
3446 Top Side Rail - Insert 1200 4 1.3 Y Y
3447 Top Side Rail - Insert 1500 2 1.5 Y Y
3448 Top Side Rail - Insert 1800 2 1.7 Y Y
3481 Top Side Rail - Straighten Any 5 0.2 N Y

NOTES:
- Times in codes 3441-3448 include welding and painting (primer + top coat).
- Top side rail thickness is 3.0mm.

3.4.5 TOP SIDE RAIL SECTIONING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
3449 Top Side Rail - Section 150 4 0.8 Y Y
3450 Top Side Rail - Section 300 4 0.9 Y Y
3451 Top Side Rail - Section 600 4 1.1 Y Y
3452 Top Side Rail - Section 900 4 1.4 Y Y
3453 Top Side Rail - Section 1200 4 1.6 Y Y
3454 Top Side Rail - Section 1800 4 2.2 Y Y
3455 Top Side Rail - Section 2400 4 2.7 Y Y
3456 Top Side Rail - Section 3600 2 3.8 Y Y
3457 Top Side Rail - Section 4800 2 4.9 Y Y
3458 Top Side Rail - Section 6000 2 6 Y Y

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3459 Top Side Rail - Section 7200 2 7.1 Y Y

NOTES:
- Times in codes 3449-3459 include welding and painting (primer + top coat), as well as
supporting of the roof for larger sections.
- Codes exclude times for replacing/re-installing the lashing rings and hanger rails. Please
use the appropriate codes; if to be replaced in connection with this repair.
- Top side rail thickness is 3.0mm.

3.4.6 HANGER RAIL SECTIONING AND REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
3331 Hanger Rail - Re-install Up to 3000 8 0.3 N Y
3321 Hanger Rail - Replace Up to 3000 8 0.5 Y Y
3351 Hanger Rail - Section Up to 600 1 0.4 Y Y
3352 Hanger Rail - Section 600-1200 1 0.5 Y Y
3431 Hanger Rail - Straighten -- 2 0.2 N Y

3.4.7 BOTTOM SIDE RAIL REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
3521 Bottom Side Rail - Replace (20ft. Container) -- 2 7.9 Y Y
3522 Bottom Side Rail - Replace (40ft. Container) -- 2 14.9 Y Y
NOTES:
- Time includes removing the damaged part, installing the new part, welding and painting
(primer + top coat) as well as supporting the floor while replacement.
- Codes exclude times for replacing/re-installing the lashing rings and floorboards. Please
use the appropriate codes; if to be replaced in connection with this repair.
- Bottom side rail thickness is 4.5mm.

3.4.8 BOTTOM SIDE RAIL INSERTING / STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
3541 Bottom Side Rail - Insert 150 4 0.9 Y Y
3542 Bottom Side Rail - Insert 300 4 1 Y Y
3543 Bottom Side Rail - Insert 450 4 1.1 Y Y
3544 Bottom Side Rail - Insert 600 4 1.3 Y Y
3545 Bottom Side Rail - Insert 900 2 1.5 Y Y
3546 Bottom Side Rail - Insert 1200 2 1.7 Y Y
3547 Bottom Side Rail - Insert 1500 2 1.9 Y Y
3548 Bottom Side Rail - Insert 1800 2 2.2 Y Y
Bottom Side Rail – Straighten
3481 Any 8 0.1 N Y
NOTE: Applied to the flange only

NOTES:
- Times in codes 3541-3548 include welding and painting (primer + top coat).
- Bottom side rail thickness is 4.5mm.

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3.4.9 BOTTOM SIDE RAIL SECTIONING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
3549 Bottom Side Rail - Section 150 4 1 Y Y
3550 Bottom Side Rail - Section 300 4 1.1 Y Y
3551 Bottom Side Rail - Section 600 4 1.4 Y Y
3552 Bottom Side Rail - Section 900 4 1.7 Y Y
3553 Bottom Side Rail - Section 1200 2 2.1 Y Y
3554 Bottom Side Rail - Section 1800 2 2.8 Y Y
3555 Bottom Side Rail - Section 2400 2 3.5 Y Y
3556 Bottom Side Rail - Section 3600 2 4.9 Y Y
3557 Bottom Side Rail - Section 4800 2 6.3 Y Y
3558 Bottom Side Rail - Section 6000 2 7.8 Y Y
3559 Bottom Side Rail - Section 7200 2 9.2 Y Y
NOTES:
- Times in codes 3549-3559 include welding and painting (primer + top coat), as well as
supporting of the floor for larger sections.
- Codes exclude times for replacing/re-installing the lashing rings and floorboards. Please use
the appropriate codes; if to be replaced in connection with this repair.
- Bottom side rail thickness is 4.5mm.

3.4.10 SIDE ASSEMBLY – OTHERS

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
6721 Lashing Rings/Bars - Replace -- 9 0.2 Y Y
6722 Lashing Rings/Bars - Straighten -- 9 0.1 N Y
Side Logo - Paint full letter
0962 NOTE: Use only if whole logo cannot be rec- -- 9 0.2 Y N
ognized and in conjunction with a repair
Side Logo - Paint full logo
0961 NOTE: Only associated with major repairs -- 2 0.7 Y N
(e.g. multiple side panels replacement)
3920 Ventilator - Replace -- 4 0.1 Y Y

3.5 Rear Assembly

3.5.1 REAR HEADER REPLACEMENT
STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
4421 Rear Header - Replace complete assembly -- 1 3.9 Y Y
NOTES:
- Time includes removing the damaged part, installing the new part, welding and painting of
the new part (primer + top coat), and fabrication and installation of corner protection
plates and cam keepers.
- Rear header thickness should be 4.0mm.

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3.5.2 REAR HEADER INSERTING / STRAINGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
4441 Rear Header - Insert 150 2 0.9 Y Y
4442 Rear Header - Insert 300 2 1 Y Y
4443 Rear Header - Insert 450 2 1.1 Y Y
4444 Rear Header - Insert 600 2 1.3 Y Y
4445 Rear Header - Insert 900 2 1.5 Y Y
4446 Rear Header - Insert 1200 1 1.7 Y Y
4447 Rear Header - Insert 1500 1 1.9 Y Y
4448 Rear Header - Insert 1800 1 2.2 Y Y
4481 Rear Header - Straighten Any 1 0.5 N Y
NOTES:
- Times in codes 4441-4448 include welding and painting (primer + top coat).
- Rear header thickness shall be 4.0mm.
- Inserting is including corner protection plates (extension plates) and gusset plates.

Sectioning of Headers and Sills is not allowed.

3.5.3 REAR SILL REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
4521 Rear Sill - Replace complete assembly -- 1 4 Y Y
NOTES:
- Time includes removing the damaged part, installing the new part, welding and painting
(primer + top coat), and removal and re-installation of surrounding floor panels and cam
keepers.
- Rear sill thickness is 4.5mm.

3.5.4 REAR SILL INSERTING / STRAINGHTENING / WELDING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
4542 Rear Sill - Insert 300 2 1 Y Y
4543 Rear Sill - Insert 450 2 1.1 Y Y
4544 Rear Sill - Insert 600 1 1.3 Y Y
4545 Rear Sill - Insert 900 1 1.5 Y Y
4546 Rear Sill - Insert 1200 1 1.7 Y Y
4547 Rear Sill - Insert 1500 1 1.9 Y Y
4548 Rear Sill - Insert 1800 1 2.2 Y Y
Rear Sill - Straighten
4582 NOTE: In connection with cam keepers misa- Any 4 0.1 N Y
lignment
Front Sill – Straighten
4581 Any 2 0.1 N Y
NOTE: Applied to Flange Only
Up to
4541 Rear Sill - Insert – Twist-lock protection cone 2 0.7 Y Y
300 mm

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6970 Threshold Plate - Repair or Replace -- 1 0.5 Y Y

NOTES:
- Times in codes 4542-4548 and 4541 include welding and painting (primer + top coat).
- Rear sill thickness shall be 4.5mm.

Sectioning of Headers and Sills is not allowed.

3.5.5 REAR CORNER POST REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
4621 Rear Corner Post – Replace (8' 6'' High) -- 2 4.4 Y Y
4622 Rear Corner Post – Replace (9' 6'' High) -- 2 4.6 Y Y
NOTES:
- Time includes removing the damaged part, installing the new part, welding and painting
(primer + top coat), and removal and re-installation of surrounding floor panels.
- Times include also removal and installation of lashing bars.
- Codes are excluding corner casting replacement; if applicable.
- Codes are excluding door reinstallation.
- Rear corner post thickness shall be 6.0mm for the outer profile, and 12.0mm for the inner
profile.
- Material for the inner profile is SM490YA (Yield Point = 370 N/mm2, Tensile Strength =
500 N/mm2)

3.5.6 REAR CORNER POST INSERTING / STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
4641 Rear Corner Post – Insert 150 2 1 Y Y
4642 Rear Corner Post – Insert 300 2 1.1 Y Y
4643 Rear Corner Post – Insert 450 2 1.2 Y Y
4644 Rear Corner Post – Insert 600 2 1.3 Y Y
4645 Rear Corner Post – Insert 900 2 1.6 Y Y
4646 Rear Corner Post – Insert 1200 2 1.8 Y Y
4647 Rear Corner Post – Insert 1500 2 2.1 Y Y
4681 Rear Corner Post – Straighten Inner Profile Any 2 1.5 N Y
Rear Corner Post – Straighten Outer Profile
4682 Any 2 0.1 N Y
Incl. J-Bar
4648 J-Bar – Insert 75 to 300 2 0.7 Y Y
4649 J-Bar – Insert 600 2 1 Y Y
NOTES:
- Times in above codes include welding and painting (primer + top coat).
- Rear corner post thickness shall be 6.0mm for the outer profile, and 12.0mm for the inner
profile.

Sectioning of Corner Posts is not allowed.

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3.5.7 REAR FRAME – OTHERS

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
4722 Corner Casting - Replace - Bottom Rear -- 2 2.3 Y Y
4721 Corner Casting - Replace - Top Rear -- 2 1.5 Y Y
4281 Rear Frame - Align frame to ISO standards -- 1 0.5 N Y
NOTES:
- Times in codes 4722 and 4721 include welding and painting (primer + top coat), and re-
moval and re-installation of floor boards when applicable.
- Time for door reinstallation is not included. Please use the appropriate code.

1 Repair of corner castings is not allowed. Only

replacement is allowed.
2 Corner Casting dimensions should be in accordance
to ISO 1161.

3.6 Door Assembly

Please refer to the latest “Guidelines to Door Locking System Repair” for more details. You can
also learn more by contacting Maersk Line EMR Manager in your location.

3.6.1 DOOR PANEL REPLACEMENT

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
1954x943
5121 Door Panel - Replace (For 8'6'' containers) 2 3.0 Y Y
T= 2.0
2259x943
5122 Door Panel - Replace (For 9'6'' containers) 2 3.2 Y Y
T= 2.0
5123 Door - Re-Install (for 8'6'' containers) -- 2 1.2 N Y
5124 Door - Re-Install (for 9'6'' containers) -- 2 1.2 N Y
5932 Door - Re-install door after dismantling -- 1 0.9 N Y

NOTES:
- Times in codes 5121 & 5122 include welding and painting (primer + top coat), and remov-
al and re-installation of door hardware and gaskets.

3.6.2 DOOR PANEL PATCHING / STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
5111 Door Panel - Patch 150x150 4 0.8 Y Y
5112 Door Panel - Patch 150x200 4 0.8 Y Y
5113 Door Panel - Patch 300x200 4 0.9 Y Y
5114 Door Panel - Patch 450x300 4 1.2 Y Y
5115 Door Panel - Patch 600x450 4 1.5 Y Y
5116 Door Panel - Patch 700x600 2 1.8 Y Y
5117 Door Panel - Patch 850x700 2 2 Y Y

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5118 Door Panel - Patch 850x900 2 2.2 Y Y

5119 Door Panel - Patch 850x1200 2 2.4 Y Y
Door Panel – Straighten
5181 Per Door 2 0.4 N Y
NOTE: 1 pcs. = 1 door

NOTES:
- Times in codes 5111 & 5118 include welding and painting (primer + top coat).
- Door panel thickness is 2.0mm.

3.6.3 DOOR FRAME

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
5131 Door Horizontal Frame – Insert 300 4 0.7 Y Y
5132 Door Horizontal Frame – Insert 450 4 0.9 Y Y
5133 Door Horizontal Frame – Insert 600 4 1.2 Y Y
5134 Door Horizontal Frame – Insert 900 4 1.5 Y Y
5141 Door Horizontal/Vertical Frame – Section 300 4 1.3 Y Y
5142 Door Horizontal/Vertical Frame – Section 450 4 1.5 Y Y
5143 Door Horizontal/Vertical Frame – Section 600 4 1.6 Y Y
5144 Door Horizontal/Vertical Frame – Section 900 4 1.8 Y Y
5145 Door Vertical Frame – Section 1200 2 2.1 Y Y
5146 Door Vertical Frame – Section 1500 2 2.3 Y Y
5147 Door Vertical Frame – Section 1800 2 2.5 Y Y
NOTES:
- Times in the codes above include door gasket re-installation, welding and painting (primer
+ top coat).
- Times for re-installation of hinges and/or brackets will be given separately. Please use the
appropriate codes for that.
- Note: Inserts for door vertical members are not allowed.
- Door horizontal members’ thickness should be 3.0mm.
- Door vertical members’ thickness should be 3.2mm.

3.6.4 DOOR GASKET

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
5728 Door Gasket – Repair cut by lap joint Per Piece 5 0.1 Y Y
From 1,000
5721 Door Gasket – Replace 4 0.3 Y Y
to 1,500
From 1,500
5722 Door Gasket – Replace 4 0.5 Y Y
to 2,300
From 500
5720 Door Gasket – Replace 4 0.2 Y Y
to 1,000
5726 Door Gasket – Replace complete gasket Per Door 2 1.2 Y Y
Door Gasket – Replace door corner tap
5727 Per 2 taps 4 0.1 Y Y
NOTE: 1 PCS = 2 CORNER TAPS
5719 Door Gasket – Replace Up to 500 5 0.1 Y Y
5731 Door Gasket Retainer – Refasten -- 4 0.1 N Y

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5921 Door Gasket Retainer – Replace Up to 1,200 6 0.3 Y Y

3.6.5 DOOR HARDWARE REPLACEMENT / REPAIR

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
5522 Bearing Bracket (Outer/Inner) – Replace -- 4 0.2 Y Y
4821 Cam or Cam Keeper – Replace -- 8 0.3 Y Y
Cam or Cam Keeper – Re-Install
5524 NOTE: Use only with inserting/replacing sills -- 8 0.3 Y Y
or headers
5221 Complete Door Hinge – Replace -- 8 0.6 Y Y
5523 Door Handle – Replace -- 4 0.1 Y Y
5422 Door Handle Hub – Replace -- 4 0.2 Y Y
5222 Hinge Pin – Replace -- 8 0.2 Y Y
5421 Locking Rod – Replace -- 4 0.7 Y Y
5451 Locking Rod – Section -- 4 0.3 Y Y
5621 Retainer Catch or Plate – Replace -- 4 0.1 Y Y

NOTES:
- Times in the codes above include welding and painting (primer + top coat) where applica-
ble.

3.6.6 DOOR HARDWARE STRAIGHTENING

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
5482 Bearing Bracket (Outer) – Straighten -- 4 0.1 N Y
5483 Cam or Cam Keeper – Straighten -- 16 0.1 N Y
Door Handle – Straighten
5581 -- 2 0.1 N Y
NOTE: 1 PCS. = 1 HANDLE
5423 Door Handle Hub – Straighten/Repair -- 4 0.1 N Y
5281 Hinge Blade or Hinge Lug – Straighten -- 8 0.1 N Y
Locking Rod – Straighten
5481 -- 4 0.2 N Y
NOTE: 1 PCS. = 1 LOCKING ROD
Retainer Catch or Plate - Straighten/Repair
5681 -- 2 0.1 N Y
NOTE: 1 PCS. = 2 CATCH OR PLATE

NOTES:
- Times in the codes above include welding and painting (primer + top coat) where applica-
ble.

3.6.7 DOOR – MISCELLANEOUS

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
Anti-Racking Blocks – Replace
5623 -- 2 0.2 Y Y
NOTE: ONLY USED WITH HIGH-CUBES
5931 Door – Dismantle for ventilation purposes -- 1 0.4 N Y
5624 Door Holdback Rope/Chain – Replace -- 2 0.1 Y Y

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5271 Free up both doors and door hardware -- 1 0.3 N Y

Door Hinges Inspection Project - 01 Pull Test
5900 -- 1 0.1 N Y
NOTE: 1 PCS. FOR BOTH DOORS
Door Hinges Inspection Project - 02 Drill &
5901 -- 8 0.2 Y Y
Lubricate Door Hinges
NOTES:
- Codes 5900 and 5901 are related to the recent door hinge issues. Such codes have to be
used with the suspicious profiles (Please refer to your Maersk Line EMR Manager to learn
more about the case, and receive the repair bulletin).

3.7 Floors
Please refer to the latest “Guidelines to Plywood Floor Repairs” for more details. You can learn
more by contacting Maersk Line EMR Manager in your location. Refer also to IICL TB003 for guid-
ance on “Finger Crack” repairs.

3.7.1 FLOORBOARD GENERAL GUIDELINES

 Floorboard material can be plywood, bamboo or a mixture of plywood and bamboo.

 Overall floorboard thickness is 28 mm (19 plies).
 Plywood species that be used include: Eucalyptus, Poplar, Birch, Beech, Pine, Larch, etc.
 Maximum moisture content shall not exceed 14%.
 Outer three plies on each side are made of Apitong or Keruing.
 Wood is chemically treated according to the requirements of the Commonwealth of Australia,
Department of Health, Australian Quarantine and Inspection Service (AQIS) [Timber Compo-
nents Treated – TCT Certificate].
 Plywood floors shall be FSC certified (Forest Stewardship Council).
 Floorboard shall pass the following tests:

o IICL Short Span Test (3.1 in IICL Performance Standard for Plywood Floor Panels –
IICL TB001).
o Bending Strength and Elastic Modulus (4.9 in GB/T 19536 2004).
o Boiling Test (GB/T 19536 – 2004).
o ISO 1496 Floor Strength Test (Truck Load of 7,260 kg).

3.7.2 FLOOR REPAIRS

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
Plywood Floor - Apply Protective Coating
6700 -- 1 0.5 Y Y
NOTE: CODE IS VALID FOR KOREA ONLY
Plywood Floor - Coating of oil-contaminated
floorboard. Up to
6170 7 0.1 Y Y
NOTE: 1 PCS. CAN COVER AN AREA UP TO 1200x1200
1200x1200 MM
Plywood Floor - Repair Holes Less than
6142 9 0.1 Y Y
NOTE: 1 PCS. = UP TO 5 HOLES 25mm
Plywood Floor - Repair Holes Less than
6141 9 0.1 Y Y
NOTE: 1 PCS. = UP TO 5 HOLES 5mm
Floor Caulking
6172 Up to 7,000 6 0.1 Y Y
NOTE: 1 PCS. = UP TO 7,000 MM LENGTH

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Floor Tapping Screws - Re-fasten

6171 -- 3 0.1 N Y
NOTE: 1 PCS. = UP TO 5 SCREWS
Floor Tapping Screws – Replace
6173 -- 5 0.1 Y Y
NOTE: 1 PCS. = UP TO 5 SCREWS

3.7.3 FLOOR PLANKS / WPC FLOOR

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
6632 PLANK Floor - Re-install 1,500 9 0.5 N Y
6636 PLANK Floor - Re-install 3,000 9 0.8 N Y
6423 PLANK Floor - Replace entire 20ft. area -- 1 12.6 Y Y
6424 PLANK Floor - Replace entire 40ft. area -- 1 27.6 Y Y
6425 PLANK Floor - Replace entire 45ft. area -- 1 33 Y Y
6622 PLANK Floor - Section 1,200 9 0.9 Y Y
6624 PLANK Floor - Section 1,800 9 1.2 Y Y
6625 PLANK Floor - Section 2,400 9 1.5 Y Y
6626 PLANK Floor - Section 3,000 9 1.7 Y Y
NOTES:
- Times in the codes above include cutting and preparing planks, as well as sealing.
- Dimensions specified for above codes indicate the plank length.
- PLANK Floor codes can as well be used with Wood-Plastic Composite (WPC) Floors.

3.7.4 PLAYWOOD FLOOR REPAIRS

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
6532 Plywood Floor - Re-install 1160x1000 2 0.7 N Y
6533 Plywood Floor - Re-install 1160x1900 2 1 N Y
6531 Plywood Floor - Re-install 1160x650 4 0.5 N Y
6534 Plywood Floor - Re-install full board 1160x2400 8 1.3 N Y
6426 Plywood Floor - Replace - Entire Floor 20ft. -- 1 10.6 Y Y
6427 Plywood Floor - Replace - Entire Floor 40ft. -- 1 19 Y Y
6428 Plywood Floor - Replace - Entire Floor 45ft. -- 1 20.6 Y Y
6520 Plywood Floor - Section - Case 7 636x750 4 0.5 Y Y
6521 Plywood Floor - Section - Cases 4/6/8 1160x650 4 0.8 Y Y
6522 Plywood Floor - Section - Case 7 636x1500 4 0.7 Y Y
6523 Plywood Floor - Section - Cases 2/8 1160x1300 2 1.5 Y Y
6524 Plywood Floor - Section - Case 9 (Full Board) 1160x2400 6 2.1 Y Y
6525 Plywood Floor - Section - Cases 1/3/8 1160x1000 4 1.2 Y Y
6526 Plywood Floor - Section - Cases 5/8 1160x800 4 0.9 Y Y
6527 Plywood Floor - Section - Case 8 1160x1600 4 1.7 Y Y
6528 Plywood Floor - Section - Case 8 1160x1900 2 1.9 Y Y
6529 Plywood Floor - Section - Case 8 1160x2100 2 2.0 Y Y
NOTES:
- For the definition of cases mentioned above, please refer to the “Guidelines to Plywood
Floor Repairs”. Contact Maersk Line EMR Manager in your location to obtain a copy.
- Times in the codes above include cutting and preparing floor panels, as well as sealing.

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3.7.5 CENTER RAIL REPAIR

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
6571 Floor Center Rail - Repair -- 4 0.3 Y Y
6352 Floor Center Rail - Replace > 1800 5 0.4 Y Y
6351 Floor Center Rail - Replace < 1800 5 0.3 Y Y

NOTES:
- Center rail is also called center spacer or center divider, and can be made from different
materials. Please repair/replace like for like.

3.8 Under-Structure Assembly

3.8.1 CROSS MEMBERS
STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
7121 Cross Member - Replace -- 27 0.9 Y Y
7141 Cross Member - Insert 150 8 0.9 Y Y
7142 Cross Member - Insert 300 8 1 Y Y
7143 Cross Member - Insert 450 8 1.1 Y Y
7144 Cross Member - Insert 600 6 1.2 Y Y
7145 Cross Member - Insert 900 4 1.3 Y Y
7146 Cross Member - Insert 1200 4 1.5 Y Y
7147 Cross Member - Insert 1500 4 1.7 Y Y
Cross Member – Straighten Cross Member N Y
7181 -- 9 0.1
Flange or Web
7182 Cross Member - Straighten and Re-weld -- 8 0.2 N Y
NOTES:
- The codes above include welding, painting (primer + top coat), and sealing where applica-
ble.
- Cross member thickness is 4.0mm, while the joint cross member thickness is 4.5mm.

Sectioning of Cross Members is not allowed.

Refer also to IICL TB007 “Limitations on Cross Member

Repairs”

3.8.2 GOOSENECK TUNNEL

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
7356 Gooseneck Tunnel - Insert 300 2 1.1 Y Y
7357 Gooseneck Tunnel - Insert 600 2 1.3 Y Y
7358 Gooseneck Tunnel - Insert 900 2 1.6 Y Y
7321 Gooseneck Tunnel - Replace assembly -- 1 8.7 Y Y
7351 Gooseneck Tunnel - Section 350 1 2.7 Y Y
7352 Gooseneck Tunnel - Section 700 1 3.3 Y Y

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7353 Gooseneck Tunnel - Section 1050 1 3.9 Y Y

7354 Gooseneck Tunnel - Section 1400 1 4.4 Y Y
7355 Gooseneck Tunnel - Section 1750 1 5 Y Y
7359 Gooseneck Tunnel - Straighten Up to 600 2 0.5 N Y
7421 Outrigger - Replace -- 12 0.5 Y Y
7482 Outrigger - Straighten and re-weld -- 8 0.2 N Y
7481 Outrigger - Straighten flange or web -- 8 0.1 N Y
7741 Tunnel Bolster - Insert 300 1 1 Y Y
7743 Tunnel Bolster - Insert 600 1 1.3 Y Y
7744 Tunnel Bolster - Insert 900 1 1.5 Y Y
7721 Tunnel Bolster - Replace -- 1 3.1 Y Y
7421 Outrigger - Replace -- 12 0.5 Y Y
7482 Outrigger - Straighten and re-weld -- 8 0.2 N Y
7481 Outrigger - Straighten flange or web -- 8 0.1 N Y
NOTES:
- The codes above include welding, painting (primer + top coat), and sealing where applica-
ble.
- Please use the appropriate codes for floorboard re-installation when applicable.
- Gooseneck tunnel thickness is 4.5mm, while tunnel bolster thickness is 4.0mm

3.8.3 FORKLIFT POCKET

STS Description Size (mm) Max. Hr./ Mat. Prep.
Codes Pcs. Pc
7541 Forklift Pocket - Insert 150 4 0.9 Y Y
7542 Forklift Pocket - Insert 300 4 1 Y Y
7543 Forklift Pocket - Insert 450 4 1.1 Y Y
7544 Forklift Pocket - Insert 600 4 1.2 Y Y
7545 Forklift Pocket - Insert 900 4 1.4 Y Y
7546 Forklift Pocket - Insert 1200 4 1.6 Y Y
7547 Forklift Pocket - Insert 1500 2 1.8 Y Y
7548 Forklift Pocket - Insert 1800 2 2 Y Y
7549 Forklift Pocket - Insert 2300 2 2.3 Y Y
7521 Forklift Pocket - Replace assembly -- 2 3.3 Y Y
7582 Forklift Pocket - Straighten and re-weld > 500 4 0.3 N Y
7581 Forklift Pocket - Straighten and re-weld Up to 500 4 0.2 N Y
7621 Strap - Replace -- 4 0.4 Y Y
7681 Strap - Straighten -- 4 0.1 N Y
7682 Strap - Straighten and re-weld -- 4 0.2 N Y
NOTES:
- The codes above include welding, painting (primer + top coat), and sealing where applica-
ble.
- Please use the appropriate codes for floorboard re-installation when applicable.
- Forklift upper strap thickness is 3.0mm, while the lower strap thickness is 6.0mm.

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4 APPENDICES
4.1 Appendix 1 – TB003 – Finger Cracks in Floorboards

IICL TB 003, 1 May 2005

Title: “Finger Cracking in Plywood Floor Boards”.
The IICL is revising the inspection criteria for plywood flooring effective May 1, 2005.
Reference: IICL “Grey Areas” Manual 2nd Ed. Section 3.4

Finger Cracking - Definition

A “finger crack” is a separation in a surface veneer running transverse combined with separations run-
ning longitudinal at both ends of the transverse separation.
Revised Criteria
Not all cases of finger cracking will be repair worthy. Finger cracking will be repair worthy only when
accompanied by one or more of the following conditions:

Visible sign of impact on the opposite side

Damage to adjacent components, i.e., cross members, sills, floor rails, and hat sections
Visible bowing of the opposite side of the floor
Hollow sound when hammer tested

IICL TB 003 was prepared under the supervision of the following representatives from IICL member
companies:
Container Applications Limited (CAI) Mike Hohndorf
Textainer Equipment Management (U.S.) Ltd. Jack Figueira
Triton Container International Ltd. Hank Heacox
Florens Container Services (USA) Ltd. Luiz Goncalves

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Centre Equipment & EMR STS Manual – Steel Dry Containers

555 PLEASANTVILLE ROAD, SUITE 140 SOUTH BRIARCLIFF MANOR, NY 10510 USA
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4.2 Appendix 2 – Revised Cross Member Repair Criteria

IICL TB 007, 23 September 2010

Title: LIMITATIONS ON CROSSMEMBER REPAIRS
Reference IICL “Repair Manual for Steel Freight Containers (fifth edition)
Section 8.2.3 Cross member Inserting
Section 8.4.3 Forklift Pocket Side Inserting
The IICL has revised its criteria for member (cross member / forklift pocket side wall) inserting as out-
lined below:

Revised Criteria
Weld repairs to members (cross members / forklift pocket side walls) are not allowed
within the center one half of two adjacent members. The center one half of a member is
defined as that part of the member that is greater than 600mm from the nearest bottom
side rail. If two adjacent members have weld repairs within the center halves, either one
of the members must either be replaced or the inserts must be lengthened such that they
do not terminate within the center half of the member.

BACKGROUND
The IICL has recently become aware of weld cracking in two repair techniques used to repair downward
bowed members (cross members / forklift pocket side walls).
The most common repair involves the installation of a series of inserts at our near the centers of several
adjacent members. The vertical welds—located near the members centers in the area of maximum bend-
ing stress and subject to the residual tension resulting from jacking the member’s straight prior to in-
stalling the inserts—may have been, in a few cases, below IICL standards.
If the sub-standard weld pulls apart, the floor load is passed to the adjacent member, and the adjacent in-
sert welds may also pull apart, resulting in a series of weld failures until all inserted members have pulled
apart.

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Centre Equipment & EMR STS Manual – Steel Dry Containers

A second, but less common, repair involves cutting relief notches at or near the members centers, jacking
the members straight, and weld the notch closed. These also may come apart for the same reasons and in
the manner as described above.

With the objective of eliminating these shortcomings, the IICL Technical Committee has revised member
repair standards so as to eliminate sub-standard inserting and other welded repairs in the highly stressed
center portions of members.

IICL TB 007 was prepared under the supervision of the IICL Technology Committee.

1990 M STREET NW, SUITE 650, WASHINGTON, DC 20036-3417 USA

TELEPHONE: 202 223-9800 FAX: 202 223-9810 WEBSITE: www.iicl.org

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