GUIDE FOR MEA INSTITUTE OF INTERNATIONALGUIDE FOR CONTAINER DAMAGE MEASUREMENT PREPARED BY: HCL Technology Committee GE SeaCo SRL AM. Brassingion (Chairman Amphibious Container Leasing Lid, R. Burns Carlisle Leasing International, LLC Loiacono Container Applications International, Inc M. Hohndort Cronos Containers Limited J. Kirby Flexi-Van Leasing, Inc M. Merezio Florens Container Services (U.S.) td. _L. Goncalves Gold Container Corporation F. Kesteloot Interpol, Ine A. Awad Textainer Equipment Management (Us) Ld A. Sowry Transamerica Leasing Inc LVitais Twiton Container International Ltd. H. Heacox Guide for Container Damage Measurement Subcommittee Triton Container International Ltd. H. Heacox (Chaieman) Textainer Equipment Management (U.S) Led. J. Figueira Global Intermodal Systems M, Baldwin STITUTE OF INTERNATIONAL CONTAINER LESSORS, LTD. PLEASANTVILLE ROAD, SUITE 140 SOUTH [BRIARCLIFF MANOR, NEWYORK 10510-1955 USA TELEPHONE: +1914 747-9100. FAX: 1 914 747-2600 E-MAIL INFOBICLORG WEBSITE: WWOWIICLORGABOUT THE GUIDE This Guide presents methods for measuring damage to a container during a container inspection. However, because any inspection depends largely upon the skill of human beings, the conditions under which itis per- formed and many other variables, the Institute and its members and personnel cannot and do not assume any liability for damage to persons or property or other con- sequences of any procedures referred to herein. CREDITS ICL wishes to thank Global Intermodal, and BY, for their active participation as members of the subcommit- tee that prepared this Guide. Thanks are also extended to Maersk Line and American President Lines Ltd. for their assistance with the field trials of the measurement methods, HICL also expresses appreciation to Carl Mezolf, A.LA., for his quick mastery of the container industry and his excellent drawings, prepared on a CAD system HOW TO ORDER IICL PUBLICATIONS Persons interested in obtaining the latest IICL order form and price lis for technical guicles and manuals on con- tainers and chassis should contact ICL at the following address, telephone, fax or e-mail: 555 Pleasantville Road, Suite 140 South, Briarcliff Manor, NY 10510, USA. Telephone: 1-914-747-9100; Fax: 1-914-747-4600; E-mail: info@iicl.org. The order form can also be down- loaded directly from ICUs website on the Internet (wwwllCLorg). The website also includes information oon the Inspector's Certitication program, reefer courses and other IICL activities and programs CONTENTS SECTION 1 INTRODUCTION AND PURPOSE SECTION 2 FUNDAMENTALS OF DAMAGE MEASUREMENT 3 2.1 Dimensional Limits for Bends, Dents and/or Bows, 3 2.1.1 Measuring Bends, Dents and Bows (Concave) ana 2.1.2 Measuring Bends, Dents and Bows (Convex Damage and Damage to Non-Linear Surfaces: “Space Out/Measure Back” Method) wr. 6 2.2 Measuring Damage to Check “Envelope” its (ISO Dimensions Plus ISO/IICL Tolerances) " 2.2.1 Using “Space Out” Method with Limiting Surface as Reference Point n 2.2.2 Checking Envelope When Reference Line Cannot Be Positioned at Limiting Surface and Over Damage. 3 2.2.3. Vatiations and Special Cases . eeeens SECTION 3 TOOLS REQUIRED FOR DAMAGE MEASUREMENT... 16 3.1, Basic Measurement Tools 16 32 Container Inspection 16 SECTION 4 MEASUREMENT METHODS FOR SPECIFIC AND UNUSUAL CASES. 19 4.1, Measurement Methods for Specific ‘Components and in Individual Cases 9 4.2. Methods of Measuring Damage to Rails... 19 4.2.1 Measuring Localized Damage to Side and End Rails. 1944 44d 442 443 444 45 4.6 46.1 46.2 4.63 464 4.6.6 4.6.7 ‘Checking Rails for ISO Dimensions 20 Measuring Bows or Gradual Deformation to Rails a ‘Measuring Damage to Headers with Corner Protection Plates 23 ‘Measuring Damage to Bottom Rail Webs... 25 Measuring Damage to Door Sills 26 Measuring Damage to Corner Posts 7 Measuring Damage to Side and Front Panels 28 Measuring Bends or Dents in Panels (Impacted from Outside). 30 ‘Measuring Bends or Dents in Panels {Impacted from Inside} i) Measuring Panel Bows. ss Calculating Cube Reduction Caused by Opposite Damage. 34 Measuring Damage to Doors a4 Measuring Damage to Roofs 36 Measuring Downward Damage on a Standing Corrugation...0 38 ‘Measuring Downward Damage on the Panel Area Between Corrugations.n..nn 39 Measuring Downward Damage on a Standing Corrugation End 2 Measuring Downward Damage on a Standing Corrugation End at the Roof Ends 4a Measuring Upward Damage on the Panel ‘Area Between Corrugations 46 Measuring Upward Damage Within Corrugations; Upward Bows to Roof Sheets; and Upward Damage to Header Extension Plates. 47 Measuring Downward Bows to Roof Sheets and Downward Damage to Header Extension Plates 49 Measuring Damage to Floors 50 Measuring Gouges for Depth Only. 50 Measuring Gouges for Depth and Width ..... 52 4.8 Measuring Damage to Understructure 4.8.1 Measuring a Direct Impact to a Crossmember Web 4.8.2 Measuring an Impact to Crossmember Web, from the Flange Side. 4.8.3 Measuring Web Damage at the Web Center 4.8.4 Measuring Crossmembers Bent in Two Locations, L 4.8.5. Separation of Crossmembers from Underside of Floor. 4.8.6 Crossmembers Outside ISO-Plus-ICL Tolerances SECTION 5 GLOSSARY OF DAMAGE MEASUREMENT TERMS. 59 60 61 62 64SECTION 1 INTRODUCTION AND PURPOSE The Guide for Container Damage Measurement has been issued in order to assist inspectors in measuring ‘damage to dry-van freight containers. Accuracy and consistency in container inspection is key to maintain- ing containers in safe and serviceable condition. Since containers constitute a vital link in the worldwide move- ment of intermodal transportation, assuring a high standard of inspection is of paramount importance to the industry. According to inspection procedures set forth in the IICL Guide tor Container Equipment Inspection, any damage discovered during an inspection must be measured and Compared to the inspection criteria included in the Inspection Guide to determine if repair is necessary. The criteria describe the acceptable limits of container damage that, when exceeded, must he repaired. Many of these limits consist of specific dimensions, such as a specified depth, width or length for a dent or other deformation. Experience in the field, however, has shown that con- tainer damage measurement can vary depending on the measurement method. Further-more, certain conditions ‘can make it difficult to measure some types of damage and therefore to ascertain if repair is required. It was felt, therefore, that a manual describing exactly how to measure damage and thereby setting a common basis, for measurement methods could be helpful in achieving, estimate accuracy. The Guide for Container Damage Measurement has been designed 1) to standardize measurement methods to assure consistent and repeatable results whenever a specified type of damage is measured and 2) to provide methods for measuring damage that is hard to measure, and 3) to clarify damage limits that are subject to misin- terpretation, This Guide does not provide criteria for determining it damage to containers requires repair. These criteria are November 2003.1 Introductionpublished only in the latest edition of the Guide for Container Equipment Inspection, issued by lICL. Since it was felt that a visual approach would be the ‘most practical, the Guide consists primarily of drawings illustrating the proper method of measuring damage to a given component, accompanied by brief explanatory text, A small selection of color photos has also been included to demonstrate tools and measurement tech- niques The manual is divided into four parts: ‘Section 2 provides basic information on methods of ‘measuring damage + Section 3 describes tools required for damage meas- urement * Section 4 provides specific information on measuring damage to different components, including defects that are hard to measure. ‘+ Section 5 includes definitions of measurement terms as applied in this Guide. The publishers make no representation that inspections carried out using the damage measurement methods recommended in this Guide will meet any specific requirements of any particular government. Container owners are reminded that they are responsible for com- plying with the procedures prescribed or approved by’ the applicable governments. Each owner should check carefully the particular requirements of its government. Inspections should be performed in compliance with all international conventions and regulations (e.,, the Convention for Safe Containers [CSC}} as well as with national and local laws, including those regulating safe- ty, the workplace, the environment, inspection and ‘working conditions (e.g, 29 U.S. Code of Federal Regulations, Parts 1910, 1917 and 1918) A complete and updated list of HCL and HCL publica tions can be obtained from ICL. For information on how to contact IICL, see the “credits” page on the back of the title page November 2003.2 Introduction SECTION 2, FUNDAMENTALS OF DAMAGE MEASUREMENT 21 Dimensional Limits for Bends, Dents and/or Bows The dimensional inspection criteria in the ICL Guide for Container Inspection Criteria fall into two categories: those for bends, dents andior bows; and those that affect ISO plus IICL tolerances on ISO dimensions, or the con tainer “envelope”. The first type—bends, bows andlor clents— constitutes by far the most common category of HCL damage criteria The limits of acceptable damage are given as a maxi- mum depth beyond which repair is required. The damage depth is measured from the point of maximum deflection within the damaged area to the original, undamaged point on the component For the purposes ofthis Guide, “depth” of damage is defined as the deflection in any direction avsay from the original, undamaged profile 2.1.1 Measuring Bends, Dents and Bows (Concave) The usual method of measuring a bend, dent or bow is to position a reference line between undamaged por- tions of a damaged component on either side of the damage. The reference line establishes the original, ‘undamaged profile of the damaged area. Normally, a ‘measurement is macle from the reference line to the point of maximum deflection within the damaged area this isthe depth of damage that is compared to the spe- Gific HCL criterion, See Figure 2.1 Often, a sharp bend or a dent is accompanied by prad- ual damage (such as bowing), and the damage measurement must include the total combined! detec tion due to both the sharp and the gradual damage. To ensure that both the sharp damage and any underlying gradual damage are captured in the measurement, stan dard practice is to run the reference line over the full length or height of the damaged component, a illutrat- ced in Figure 2.1. In the case of a damaged side panel, November 20033 Fundamentalsfor instance, the reference line would be run from just below the weld joining the top rail to the panel to just above the weld joining the bottom rail to the panel, There are certain exceptions to this standard practice. In some cases, there is additional damage to the compo- ‘nent so that the reference line cannot be positioned at the ends), or the component is so long that itis not practical to position a reference line over its entire length. In these cases, and provided the damage is, purely local, the reference line need not extend over the entire length of the component. However, the reference line must not be placed over only the immediate area of the bend or dent without including the larger area with the accompanying gradual damage (as shown in Figure 2.2), Restricting the reference line to the area of dam- age will fail to establish the original profile of the damaged component and will therefore result in an incorrect plane of reference for measuring the damage. As stated above, the reference line must extend between ‘wo undamaged portions of the component on either side of the damage s0 as to provide a correct plane of reference for the damage measurement. If, on the other hand, there is bowing over the entire length of the component, as in the case of a full-length top side rail bow, the reference line must extend the full length of the component. If the corner fittings are not thrown out of proper alignment by the damage, their surfaces usually make good anchors for the ends of the reference line In either case, the reference line must be positioned directly over the point of maximum damage to insure that the full depth of the damage is measured. Figure 2.3 shows the reference line correctly placed directly over the point of maximum damage. Figure 2.4 shows the reference line incorrectly placed beside the point of maximum damage, so that the full depth of the damage is nat measured. November 20034 Fundamentals CORRECT! AEFERENCE UNE EXTENDS BETWEEN. Uwonvageb SECTIONS OF THE COMPONENT were sioe OF THe bastace \UNOAMAGED PORTIONS OF CoMPONEN SF couronent [ares es ton SIDE VIEW Fig, 2.1/Correct placement of reference line: full damage measured. See Section 2.1.1 November 2003.5 FundamentalsWRONG! fortenor NN ome reesence une ‘de view Fig. 2.2/INCORRECT placement of reference line: full damage NOT measured. See Section 2.1.1 2.1.2 Measuring Bends, Dents and Bows (Convex Damage and Damage to Non- Linear Surfaces: “Space ‘Out/Measure Back” Method) ‘Two exceptions exist for the measurement method described above in Section 2.1.1: first, when damage is convex with respect to the reference line that is, when damage extends out into the path of the reference line); and second, when the damage occurs on a non-linear surface. The first exception is explained below and in 2.1.2.1, and the second in 2.1.2.2. In addition, there are cases where the reference line cannot be placed directly over the damage because adjacent components would extend into the reference line. ‘When convex damage cannot be measured from the ‘opposite side (with the reference line positioned on the ‘concave side, as described in Section 2.1.1), the “space ‘out/measure back” method should be used. The reler- ence line is “spaced out” (i.e, placed away) from the ‘component by a known distance in order to clear all obstacles. “Spacers” of a known thickness (height) are used to position the reference line away from the dam- aged component. A spacer is placed on either side of a November 2003.6 Fundamentals ‘CORRECT! a reoeeee aN oP view (CORRUGATED PANEL} ‘SDE VIEW (CORRUGATED PANEL) 2.3/Correct placement of reference line: placed over point of damage. See Section 2.1.1 November 2003 7 FundamentalsWRONG! ‘Oven Poe oF GRESTESTbeFLECTION fr ae (ro tat tert oF pow ease incomecriy GruasatBAA® —\_omomat vipauaces Dertecron oP view (CORRUGATED PANEL) ‘SIDE view (CORRUGATED PANEL) Fig. 2.4/INCORRECT placement of reference line: NOT placed over point of maximum damage. See Section 21d November 20038 Fundamentals component, and the reference line is extended from the top surface of one spacer across to the top surface of the second spacer. A measurement is then made from the reference line to the point of maximum deflection wit: in the damage. This measurement is then subtracted from the distance that the reference line has been spaced out from the component to determine the actual clepth of the damage. For the purposes of this manual, this method will be referred to as the “space ouvmeas- ture back” method, For the drawings in this manual illustrating situations ‘where damage measurements that are made by calcula- tion, such as in the method described above, the capital letter “5” will denote a spacer thickness, “M” a meas- tured dimension; and *D” a calculated dimension of damage. 2.1.2.1 Using Space Out/Measure Back Method to Measure Damage in Two Directions Figure 2.5 shows the space out/measure back technique used to measure web damage to a crassmember that has been bent in two directions. The string line cannot be placed directly on either side of the web because the adjacent damage interferes with running the line over the entire length of the crossmember. Consequently, the reference line is spaced back from the crossmember web (in actual practice, the reference line is held against the bottom side rail webs a known distance away from the crossmember web), and the damage is determined bby measurement and calculation as shown in the figure. 2.1.2.2. Measuring Damage on Non-Linear Surfaces, (Roof Sheets) The second case where damage cannot be measured sing the common method described in Section 2.1 involves the measurement of damage on non-linear sur- faces (i.e, roof sheets). Because the reference line is straight, it cannot follow the original curved surface of the roof sheet; therefore; the original undamaged posi- tion of the damaged surface cannot be precisely determined. To provide a common framework for assessing this type of damage and to assure consistent field measurement results, this Guide recommends that the curvature of the roof sheet in such cases be ignored: the reference line should simply be placed across the November 20039 FundamentalsDE Fig, 2.5/Measuring crossmember web damage when tef- erence line cannot be placed along web. See Section 2424 November 2003 10 Fundamemals entire length of the damaged! component, and the meas- turement taken from reference line to the point of maximum damage just as in Section 2.1. The reference line should be placed on the concave side of the dam- age. If this is not possible, the reference line may be placed on the convex side of the damage, and the “space out/measure back" method of measurement used Figure 2.6 (on next pagel shows an upward bend on the interior surface of a roof sheet in the flat area between corrugations. As the camber (curvature) of the roof can not be followed by the reference line, the damage ‘measurement is made from a reference line placed hori- zonially across the roof sheet width, and roof camber is ignored. 2.2. Measuring Damage to Check “Envelope” Limits (ISO Dimensions Plus ISO/ICL Tolerances ) In the cases discussed above, it was necessary to meas- ure the depth of damage and compare to the permissible limit for that component to determine if repair was required. Certain IICL criteria, however, are rnot based on acceptable limits for a particular bend, dent or bow. Instead, they require that the damage not pass beyond certain prescribed limits defined by ISO, with added tolerances permitted by IICL (“IICL toler- ances’), These criteria, commonly known as the “out-of-1S0” and “into-container-cube" limits, are also measured with the use of a reference line. Instead of measuring a dent to ascertain ifthe depth exceeds a limit, the damage is measured to see if it exceeds SO dimensions and ISO plus 1ICL tolerances. In these cases, the reference line is used to establish the limiting, surface (as, for instance, corner fitting faces) and the damage is checked to see if it reaches that limit 2.2.1. Using “Space Out” Method With Li Surface as Reference Point Figure 2.7 shows a situation in which an impact to a comer post has pushed material outward so that it could possibly exceed the IICL criteria for end frame dimen- sions of “ISO + 5 mm (3/16 in)”: that is, no end-frame: damage may extend more than 5 mm (3/16 in) beyond the vertical plane defined by the vertical surfaces of the comer fittings. In this case, the reference line is spaced ‘out 5 mm (3/16 in) from the comer fiting surfaces, and ing, November 200311 Fundamentalsie SIDE RAIL REFERENCE LINE UPWARD ROOF DAMAGE ON FLAT AREA BETWEEN CORRUGATIONS DENT DEPTH Fig. 2.6/Measuring upward damage on roof: flat area between corrugations. See Section 2.1.2.2. the damage is checked to see if it reaches the reference line. If it does, repair is required. This method is ilus- trated in Figure 2.74. Ii the inspector does not have a spacer exactly 5 mm (3/16 in) thick, he may use any two spacers of equal thickness greater than 5 mm (3/16 in}, and use a varia tion of the “space ou/measure back” method. Figure 2.78 illustrates this method November 200312, Fundamentals 2.2.2 Checking Envelope When Reference Line Cannot Be Positioned at Limiting Surface and Over Damage In some cases, itis not possible to position a reference line both at the limiting surface, such as the corner fit tings, and directly over the damage. For example, this usually happens in the case of panel bulges, where the reference line cannot be positioned! from the comer fit tings over the damage. As a consequence, itis not possible to check directly if the damage reaches a refer fence line such as is illustrated in Figure 2.7 and thus “out-of-1SO” (ie., exceeds the envelope or the ISO- specified dimension and tolerance plus the additional tolerance permitted under IICL criteria. To provide a standardized method for checking the envelope when the reference line cannot be placed in a position that makes direct measurement possible, ICL has developed an indirect measurement procedure. reference line is placed in a location where itis possible to measure deflections. The maximum allowable dis- tance between this line and the envelope limit is defined using assumptions about typical material pro- files. This distance is called the ‘reference dimension.* The distance between the reference line and the maxi- ‘mum point of damage is measured and then compared to the reference dimension. If the measurement is greater than the reference dimension, the dent or other damage exceeds the permissible limit, is “out-of-1SO" and must be repaired Figure 2.8 illustrates this method as it applies to an out ward dent in an outboard side panel corrugation. The figure illustrates a situation where an inspector suspects that the dent, which bulges out from the outboard corru- gation, might exceed the ICL criterion (“ISO tolerances plus 10 mm [3/8 inl"); in other words, the bulge might protrude more than 10 mm (3/8 in} beyond the plane defined by the side vertical surfaces of the corner fit- tings. The inspector cannot space out a reference line 10 mim (3/8 in) beyond the comer fittings and at the same time place it directly over the damage, because the damage is not directly in line between the two cor ner fitting surfaces. ‘The method recommended by this Guide is to place the reference line vertically on the inside surface of the out- board corrugation starting as close as possible to the November 200313, Fundamentals[A eee Ogre Baie by Nit ce | f+ Fig, 2.7/Using a spacer to determine if comer post dam- age exceeds ISO + IICL tolerances. See Section 2.2.1 A ceil | i | il Nv Mh Mh iA ti WA nsoano conmearion —— sernence ve react — Poet (Mer or euteono iv i at Fig. 2.8/Checking ISO + IICL tolerances when reference line cannot be positioned between two corner fittings ver point of maximum damage. See Section 2.2.2 ‘weld joining top ral to panel, and extending down to the weld joining bottom rail to panel. The bend, dent ‘or bow depth should be measured in the standard way, from reference line to the point of maximum damage. The assumption is made that the interior surface of an undamaged outboard corrugation is located & mm (3/8 in) inwards of the outside vertical face of the corner fit- tings. The reference dimension in the case illustrated in Figure 2.8 is 18 mm (11/16 in). Therefore, if the measurement exceeds 18 mm (11/16 in), the outward bulge exceeds the ISO + 10 mm (3/8 in} criterion, and must be repaired, November 2003.14 Fundamentals 2.2.3. Variations and Special Cases The categories described above—measuring bends, dents and/or bows for damage limits, and measuring to check the envelope—cover most damage measurement situations, There are many variations of the fundamen- tal measuring techniques as well as a few special cases that require a different approach. Section 4 of this Guide will describe these variations in measurement methods and the techniques that can be used to handle cases where the basic procedures in this Section cannot be followed. November 200315 FundamentalsSECTION 3. TOOLS REQUIRED FOR DAMAGE MEASUREMENT 3.1 Basic Measurement Tools Damage measurement requires a certain minimum num: ber of tools. The inspector should keep these tools on hand at all times when inspecting a container. Basic measurement tools consist of the following: 1. Retractable reference line of at least 2.9 meters (9.5 feet), with magnet attached to end 2. Damage scale. This generally consists of a ruler of at least 150 mm (6 in), preferably with gauges for 5 mm 6/16 in) and 15 mm (9/16 in) gouges attached. 3. Several magnetic spacers of various heights or thick- nesses (some spacers have protruding pins of varying heights to which reference lines can be attached, as in the photos on page 50) 4, Taper gauge (a triangular flat bar which shows the increasing width measurements away from the point ed end) 5. Standard tape measure, approximately 3.5 m (12.5 ft The following other tools or equipment are also required for general container inspection, and should be kept on hand at all times during a container inspection: 1. Corrosion testing hammer (having a tapered end with a rounded point) 2. Aluminum weather-esistant clipboard The top photo on page 18 illustrates the tools listed above. 3.2. Recommended Additional Tools for Container Inspection In addition to the basic tools required for damage meas turement and general container inspection, an inspector should have access to a number of other tools that are needed for less common measurement situations. These additional tools, although not required to be in the inspector's possession at al times as are those listed in Section 3.1 above, should be readily available in the depot where the inspections are performed. They are: November 200316 Tools Required 1, 415.3 meter (50 feet) retractable chalk line or string line A15.3 meter (50 feet) measuring tape A small autofocus camera Chalk and/or magnetic clip and note paper ‘A multi-purpose folding tool, such as a "Leatherman’ tool or Swiss Army knife: 6. ICL inspection manuals. To obtain guides and man- uals from IICL, see the “Credits” page (back of title page See the bottom photo on page 18 for an illustration of some of the tools listed above in this section, November 200317 Tools RequiredBasic measurement tools for a container inspector. At the left, from top to bottom: a retractable reference line with a magnet attached to end and three magnetic spac: ers with protruding, notched pins of different heights for holding the reference line. In the center: a taper gauge and a damage scale with 5 mm (3/16 in) and 15 mm (9/16 in) gauges attached. At the far right: a corrosion testing hammer and a standard 3.5 m (12.5 ft) tape measure, The tools are resting on weather-resistant clip board. See Section 3.1 Recommended additional tools for container inspection. Clockwise, starting at top right with red knife: a Swiss Army knife; a multi-purpose folding tool (Leathererman's tool); a 15.3 m (50 it) retractable string line with magnet attached to end; a 15.3 m (50 ft) retractable measuring, tape; and a small autofocus camera. In the center: chalk and a magnetic clip and note paper. See Section 3.2. November 200318 Tools Required SECTION 4 MEASUREMENT METHODS FOR SPECIFIC AND UNUSUAL CASES 4.1. Measurement Methods for Specific Components and in Individual Cases This section describes how to apply basic damage measurement methods to specific components and situ- ations, and what methods fo use in unusual or dificult cases. Components covered include rails, corner posts, side panels, doors, roof panels and roof sheets, floors and crossmembers, 4.2. Methods of Measuring Damage to Rails To measure damage to rail, follow the basic methods described in Section 2, “Fundamentals of Damage Measurement”. Figures 4.1 - 4.5 illustrate these meth- ‘ods as applied to specific cases of damage to rails. 4.2.1. Measuring Localized Damage to Side and End Rails As explained in Section 2, placement of the ends of the reference line to measure damage to aside rail depends upon the type of damage encountered. If damage to a side ral is localized, as in the case of a downward bend ‘over a small portion of a flat-bar top side rail, a refer ence line is positioned between the undamaged portions of the damaged rail on either side of the damage, as shown in Figure 4.1. In this case, since itis clear that there is no overall downward bow of the entire side rail the reference line does not need to extend across the entire length of the rail. When the reference line is in place, a measurement is made from the line to the point (of maximum deflection (see Figure 4.1 and Section 240 On the other hand, if there is localized damage to an ‘end rail, the reference line must be placed over the full length of the rail November 2003 19 Specific and Unusual Casesig. 4.1/Measuring localized damage to top ral. See Section 4.2.1 4.2.2. Checking Rails for ISO Dimensions Figure 4,2 illustrates a situation where a top side ral has an outward bow which the inspector suspects may’ exceed the IICL criteria for ISO dimensions and toler ances (ISO plus 10 mm [3/8 in})._ In this case, the “space out” method must be used. The reference line is spaced out 10 mm (3/8 in) from the surfaces of the cor- ner fittings; if the damage touches the reference line, the container is “out-of-ISO" and must be repaired (See Figure 4.2 A and Section 2.2), If spacers measuring 10 mm (3/8 in) in thickness are not available, the inspector can use spacers of any thickness ‘over 10 mm (3/8 in) that places the reference line out November 2003 20 Specific and Unusual Cases beyond the damage, and can apply the “space ‘outmeasure back” method shown in Figure 4.2 B. In the example shown in this drawing, a reference line is positioned using spacers measuring 13 mm (1/2 in) in thickness, 3 mm (3/8 in) more than the IICL limit over ISO tolerances. In the situation illustrated on the bot- tom left drawing in Figure 4.2 B, a measurement from the reference line back to the point of maximum out- ward deflection shows more than 3 rm (1/8 in} between line and bow. Since the spacer thickness minus the measurement from the reference line to the point of maximum deflection is less than 10 mm (3/8 in), the bow is within the IICL plus ISO tolerances and repair is not required, The bow in the drawing on the bottom right of Figure 4.2 B, however, does require repair: measurement reveals that fess than 3 mm (1/8 in) remains between reference line and point of maximum bowing when a 13 mm (1/2 in) thick spacer is used. This means that the bow extends a litle over HICL’s 10 mn (3/8 in} limit beyond the surface of the commer fitings and therefore exceeds the IICL tolerance of 10 mm (3/8 in) beyond 150. See Section 2.2 for basic instructions in the “space ‘outimeasure back” method of checking the ISO envelope. 4.2.3. Measuring Bows or Gradual Deformation to Rails I there is bowing over the entire length of a side or end rail, the reference line must extend over the full length of the rail. When measuring bow deformation, do not forget to include any accompanying bend or dent depths in the measurement, See the top color photo on page 22. November 2003-21. Specific and! Unusual CasesMeasuring bows to ral: the inspector measures distance from reference line to point of maximum deflection in a fla-bar top side rail. In the case of hows, the reference line must be extended across the full length ofthe ral. See Section 4.2.3 Measuring damage to side panels: the inspector measures a dent to a side pane! impacted from out side, Note that the reference line extends vertically cover the full height ‘of the panel. See Sections 2.1.1, 44 and 4.4.1 November 2003 22 Specific and Unusual Cases Measuring damage to comer posts: the inspector measures the distance irom reference line to point of maximum deflection in a comer post bow. The reference line extends over the fall height of the post. See Section 4.3 4.2.4 Measuring Damage to Headers with Corner Protection Plates The location of the comer protection plates may prevent a reference line from being positioned over the full length of the header. In this case, the reference line may be placed on the corner protection plates where they overlap the header, and the damage depth ("D") is determined by subtracting the thickness of the corner protection plates from the measurement between refer ence line and point of maximum damage. The reference line may also be placed on the top surfaces of the comer fittings, as shown in Figure 4.3, and the depth of damage can be calculated using the “space ‘oul/measure back” method: the distance from rail to comer fitting top surface is subtracted from the dimen- sion between reference line and point of maximum damage. November 2003.23 Construction and Usageeet eee weanen OEWTS fe f ppoe 710. | Fig. 4.3/Measuring damage to top header when corner protection plates prevent placing reference line over ful length of header. See Section 4.2.4 LO 1 wT November 2003 24 Specific and Unusual Cases 4.2.5. Measuring Damage to Bottom Rail Webs Figure 4.4 illustrates several different situations involv ing measurement of damage to bottom rail webs. ‘Whenever possible, the relerence line should be placed so that the damage extends away {rom the reference line ‘and the maximum deflection of the web may be easily measured. Ifthe flange is in the way and makes it impossible to measure the web deflection, use the method illustrated in Figure 4.28. Although the flange may be deflected, only damage to the web should be measured. Flange deflections should be ignored. {soTTOU Sie RAL OAMAGE Fig, 4.4/Measuring damage to bottom rail web, See Section 4.2.5, November 2003 25. Specific and Unusual Cases4.2.6 Measuring Damage to Door Sills Damage to a door sill should be measured by running the reference line across the full length of the sill, as is required for a transverse rail, and measuring the dis- tance from the line to the point of maximum deflection In some cases, however, it may not be possible to posi- tion the reference line in such a manner. Figure 4.5, for instance, shows a damaged door sll in which the sill ‘cut-outs prevent placing the reference line over the full length of the sill. In this situation, the inspector should position the reference line on the outer surfaces of the ‘comer fitings and calculate the extent of damage with the “space out/measure back” method iti /weosrmo! \ sl a Stor Neer REAR VIEW OF BOOR SILL iW OF DOOR SitL WITH Si CUT-OUTS ig: 4.5/Measuring damage to door sill where sill cut- ‘outs prevent placing reference line over full length of sill. See Section 4.2.6 November 2003 26 Specific and Unusual Cases 4.3 Measuring Damage to Comer Posts Damage to a comer post is measured by positioning a reference line over the entire length of the post and measuring the distance from the line to the point of maximum deflection. In some cases, damage to corner posts that protrudes (“bulges”) outward may exceed applicable IICL plus ISO tolerances (ISO plus 5 mm 1/6). The 5 mm (3/16 in) additional tolerance applies to both the end surfaces and the side surfaces of each post, since the entire post is part of the end frame. In order to determine if the container is “out-of ISO,” the inspector should space the reference line 5 mm (3/16 in) out from the appropriate surface (end or side) of the corner fit tings to establish the envelope limit. the damage touches the reference line, repair is required, Figure 4.6 shows a typical dent-and-bulge to a comer post, and illustrates the two measurement methods described above If5 mm (3/16 in} spacers are not available, any spacers of a known dimension greater than 5 mm (3/16 in) may be used. The “space out/measure back” method should be used to determine if the container exceeds the lICL plus ISO criterion. Since the limit of permissible dam- age is 5 mm (3/16 in) beyond the surface of the corner fittings, any damage which extends beyond that limit must be repaired. To determine if repair is required, the distance from the reference line to the point of maxi- mum damage is measured; if this dimension is less than the amount by which the spacer exceeds 5 mm (3/16 in), repair is required. For instance, if a 13 mm (1/2 in) thick spacer is used, the post would require repair ifthe dimension from line to damage is less than 8 mm (5/16 in), See Figures 2.7 and 4.6 (pages 14 and 28), and the color photo on page 23. November 2003 27 Specific and Unusual Casescamenrome OO mines O| Ooms LO cere OF comer ne Fig. 4.6/Measuring damage to comer posts See Section 4.3 4.4. Measuring Damage to Side and Front Panels The general measurement method for panels differs from that used for structural members such as rails and posts, in that the reference line must be positioned over the entire height of the panel whenever possible. In other words, any type of damage to panels, including bends, dents and bows, requires the reference line to be placed over the full height ofthe panel, The line should be positioned vertically, from top to bottom of the panel HICL criteria for panels, however, are different for local: ized damage such as hends or dents, and for gradual damage over the length of a panel, such as bowing, Inspection criteria for bends and dents consist of specif ic depth limitations. All types of panel damage are subject to limits on reduction of the interior cube, as well as by ISO plus IICL tolerances, November 2003 28 Specific and Unusual Cases For color photos showing measurement of side panels, see the bottom photo on page 22, the photo below and the photo on page 30. ‘Measuring dents to side panels impacted from the outside: the Inspector measures the distance from reference line to point of ‘maximum inward deflection. Note that the reference line extends vertically over the full height ofthe panel See Section 4.4.1 November 2003-29 Specific and Unusual Cases‘Measuring dents to panels impacted from the inside: the inspector inside the container measures the distance frorn ret erence line 10 point of maximum outward deflection. Note thatthe reference line extends vertically over the fll height of the panel, See Section 4.4.2. 4.4.1. Measuring Bends or Dents in Panels (Impacted from Outside) As stated above, bends and dents in panels must be measured by extending the reference line vertically over the entire height of the panel trom top to bottom, and ‘making a measurement of the distance from the refer tence line to the point of maximum deflection, as shown in the photo on page 29. As explained in Section 2.1.1 the reference line must be placed directly over the point of maximum damage. Figure 4.7 illustrates this meas- turement method as applied to two common examples ‘of panel damage. In these examples, the damage is {rom outside the container extending inwards, As men- tioned in Section 4.3 above, the repainworthiness criterion is based on the depth of the dent or bend, November 2003 30 Specitic and Unusual Cases SEND AND CENT MEASUAEVENT. PE COMUDATEN , Fig, 4.7/ Measuring dents in side panels, See Section 441 4.4.2. Measuring Bends or Dents in Panels (Impacted from Inside) The same method as described above in Section 4.4.1 should be used to measure damage from the inside of the container extending outwards, as shown in the photo on page 30. In this case, however, both the depth limitation and also the ISO plus IICL tolerances ‘must be considered. If damage extends beyond the [SO cube plus the additional ICL 10 mm (3/8 in) tolerance, it must be repaired. The procedure recommended by HCL for determining if the damage exceeds ISO plus ICL tolerances is illustrated in Figure 4.8, and is explained further in the following section November 2003 31 Specific and Unusual CasesSmRanon Fig. 4.8/ Measuring side panel bows to determine if SO. +IICL tolerances are exceeded. See Sections 4.4.2 and, 443. 4.4.3. Measuring Panel Bows When a side panel has a gradual bow but no dent or bend, repair is required if the damage causes the con- tainer to exceed the ISO plus IICL tolerance of 10 mm (GV in}. Thatis, the outward damage may not extend more 10 mm (3/8 in} beyond the plane of the corner fit- ting side surfaces. In practice, it can be difficult to locate the ISO plus 10 mm (3/8 in} plane that delineates the permissible limit. As explained in Section 2.2.2, this Guide recommends a simplified and standardized procedure that can be used for determining if outward side panel bows in dry van containers exceed the ISO plus ICL 10 mm (3/8 in) limit: the damage is measured against a suitable refer- tence line, and this measurement is compared to a November 2003 32 Specific and Unusual Eases reference dimension that includes ISO plus HCL toler- ances. In the case of outward side panel bows, the reference dimension is 18 mm (11/16 in)._ If an outward bow, measured from the interior of an outboard corruge: tion (i.e., a corrugation which is recessed when viewed from inside) exceeds 18 mm (11/16 in) in depth, the bow extends out beyond ISO plus IICL tolerances for the container exterior and must be repaired The reference line should be positioned from the inter: or of the container in the outboard (recessed) corrugation over the entire height of the panel and over the maximum point of deflection. The depth of the bow is then measured from the reference line to the damage. This method is ilustrated in Figure 4.8 A The HICL tolerance limit for front panels is ISO plus 5 mm (3/16 in). The same standardized procedure described above should be used for determining if bows to front panels of dry van containers exceed ISO plus HICL limits, except that the reference dimension is reduced to 13 mm (1/2 in) (because of the lower amount of tolerance allowed over 150). ‘An inward bow (i.e, bulging from the outside into the interior of the container is limited by 1ICL inspection Criteria to a 50 mm (2 in) intrusion into the container Cube or interior width. To measure for intrusion into the ‘cube, the reference line is placed from the outside of the container into an inboard corrugation (a corrugation ‘which is recessed when viewed from the exterior of the container) and positioned over the entire height of the panel from top to bottom, and over the point of maxi- mum damage. If the bow, when measured inwards from the reference line, exceeds 50 mm (2 in), repair is requited. This method is illustrated in Figure 4.8 B. Note that the criteria described above for cube intrusion applies only when there is a bow without any dent or ‘bend. If the panel is also dented or bent, the lower dent limits apply. In that case, measure the dent as described in 4.4.1 above November 2003 33. Specific and Unusual Cases4.4.4 Calculating Cube Reduction Caused by Opposite Damage Its possible for the cube or internal width of the con- tainer to be reduced by more than 50 mm (2 in) without this limit being exceeded by any one dent, bend or cother form of damage. This occurs when inward dam- age on opposite walls totals more than 50 mm (2 in) when added together For the purposes of this manual, “opposite damage” is defined as two or more incidents of inward damage on inboard corrugations that are directly opposite to each other. Furthermore, the opposite damage must be locat- ced vertically within a 200 mm (8 in} band on either side of the container measured from the floor surface of the container. Inward damage on opposing panels that does not fall within this band is not considered “oppo- site”, and is therefore subject to the single damage criteria covered above in Sections 4.4.2 - 4.4.3 Figures 4.9 and 4.10 show how to measure opposite damage on panels. Each individual dent, bend or bow ‘must he measured from the outside using the standard reference line methods for measuring damage to panels, 4.5. Measuring Damage to Doors The method of measuring damage to door panels is the same as that used for side and front panels described above. A reference line is placed over the full width or height of the panel, and a measurement is made of the distance from reference line to maximum point of dam- age. Damage to door frames is also measured by placing the reference line over the full width or height of the frame and measuring damage depth from the reference line. November 200334 Specific and Unusual Cases aN Fig, 4.9/Measuring opposite dents in side panels. See Section 4.4.4 November 2003 35. Specific and Unusual Casesee pense | a \ RST ASE Ee Sm J 77, Yf-wn osm ag Petree miacreeneslen Fig, 4.10/Measuring opposite damage to determine if interior cube is reduced by more than 50 mm (2 in). See Section 4.8.4, 4.6 Measuring Damage to Roofs The container roof presents some of the most challeng- ing measurement problems in container inspection. First, the camber or curvature that is built into all con- tainer roofs as well as the flexibility of container roof panels makes it difficult to locate a reference plane. As explained in Section 2.1.2.2, this Guide recommends certain standardized procedures for measuring non-lin- ear surfaces such as container roofs. However, since methods of measuring damage to roofs vary according, to the location and direction of the damage, each type Of situation is described separately in the following sub- sections. November 2003 36 Specific and Unusual Cases ‘An additional challenge in determining if a container roof requires repair is presented by the subtle variations in the NCL criteria for repainworthy roof damage. Table 5.5 in the Guide for Container Equipment Inspection, Sth edition (IICL-5), provides several diferent roof inspection criteria, according to the type and location of the damage, as follows: + Header extension plate: bends, dents, bows or a Combination of these are subject to two limits 50 mm (2 in} for intrusion into the cube in the downward direction 180 plus HICL tolerance of 10 mm (3/8 in) in the ‘upward direction* There is no other dent limitation. + Roof panek: bends or dents (alone or in combination with a bow) are subject to two limits: 35 mm (1-3/8. in) depth in any direction (up or down) ISO plus IICL tolerance of 10 mm (3/8 in) in an upward direction* * Roof bows: hows (with no accompanying dents or bends) are subject to two limits: 50 mm (2 in) for intrusion into the cube in the downward direction. ISO plus IICL tolerance of 10 mm (3/8 in) in the upward direction” The 35 mm (1-3/8 in) depth limit does not apply when the damage consists of a bow only, and does not include a dent or bend. The terms “header extension plate”, “standing corruga- tions” and the “panel area between corrugations”, ‘which will be referred to throughout this section, are illustrated in Figure 4.11 * In general, the maximum height of any part ofthe roof, Including the extra ICL tolerances, is 4 mm (5/32) above the plane of the top surfaces ofthe top corner fittings. If any part ‘of the roof extends higher than this limit, repair i required November 2003 37 Specific and Unusual CasesOOF comPoNENTS Fig 4.11/Location of container roof components. See Section 4.6 4.6.1. Measuring Downward Damage on a Standing Corrugation As stated in Section 2.1.2.2, this Guide recommends that roof camber (curvature) be ignored when measuring roof damage. In the case of downward damage on a standing, roof corrugation, the damage depth is meas- ured from the reference plane of the corrugation ends The reference line is extended along the corrugation from just inside the radi at the tips of the formed ends of the corrugation. A measurement is then made of the distance from the reference line to the point of maxi- ‘mum downward deflection. Figure 4.13 and the top photo on page 41 illustrate this method In some cases, the ends} of the corrugations will be ‘damaged and therefore cannot be used to position the reference line. In this case, the reference line is spaced Up from the top surfaces of the top side rails to clear the roof completely. The distance from the reference line to an undamaged corrugation end is measured just inside November 2003 38 Specific and Unusual Cases the corrugation end radius. A second measurement is made from the reference line to the deepest point in the damage. The first measurement is then subtracted from the second to calculate the depth of damage. Figure 4.12 below describes this method 4.6.2. Measuring Downward Damage on the Panel ‘Area Between Corrugations Damage to the panel area between corrugations on a roof is measured as described in the section above, except that the reference line should be placed between the standing corrugations and extend across the roof from just inside the welds at either side of the roof sheet, as in Figure 4.13. The bottom photo on page 41 illustrates this method. a z aa bg (ea oe 5 Te 3¢ BS 83 22 a ag gy a a ee 5 ae He 1. 22 3 oO” Tas ogy ~ 2-2 sey _F & se 588 : 2 2 #2 us Weenies 232 ¥ g e 4 fl sf ze Noweriber 2003 $9 Spectlc and Uva ComaMeasuring downward damage on a standing roof corrugation: the inspector measures the distance from reference line to point of maximum downward deflection, Note thatthe refer tence line extends along the corrugation across the full width noweneine mca, fe of the root. See Section 4.6.1 7 as et Fig, 4.13/Measuring downward damage on roof pane! standing corrugations and flat areas between cortuga- tions, See Sections 4.6.1 and 4.6.2. ‘Measuring downward damage on the flat panel area between ‘corrugations: the inspector measures the distance from refer ence line to point of maximum downward deflection. Note that the reference line has been placed on the flat panel area between corrugations, and extends across the full width of the roof, See Section 4.6.2 November 2003 40. Specific and Unusual Cases November 2003 41. Specific and Unusual Cases4.6.3 Measuring Downward Damage on a Standing Corrugation End When the end of a standing corrugation has been dam- aged, the reference line should be placed on the nearest undamaged corrugations on either side of the damaged corrugation and extended across the damaged area, ‘The depth of damage is measured from the reference line down to the point of maximum deflection, as shown in Figure 4.14. yf Loo oer Fig. 4.14/Measuring downward damage on standing corrugation end. See Section 4.6.3. November 200342 Specific and Unusual Cases 4.6.4 Measuring Downward Damage on a Standing Corrugation End at the Roof Ends ‘When the end of the last corrugation on either end of a oof sheet is damaged, itis not possible to use the method described above in Section 4.6.3._In this case, the procedure illustrated in Figure 4.15 is recommend- ced a spacer is placed on the flat panel area on the opposite side of the nearest undamaged corrugation, and a spacer of equal height is placed on the flat panel area adjacent to the damaged corrugation, The refer- ence line is extended between the two spacers over the damaged area. The inspector should first measure the distance from the reference line to the undamaged cor- rugation (shown as dimension “M" in Figure 4.15), and then from the reference line to the point of maximum, damage (shown as dimension “M." in Figure 4.15). The first measurement is subtracted from the second to cal- culate the depth of damage. See the color photos on pages 45 and 46 for an illustra- tion of this method November 2003 43. Specific and Unusual CasesFig. 4.15/Measuring damage to standing corrugation at roof ends, when end of last corrugation is damaged. See Section 4.6.4, November 2003 44 Specific and Unusual Cases, Measuring downward damage on a standing corrugation end at root ends, Step #1: one spacer has been placed on the flat panel area on the opposite side of the nearest undamaged cor rugation, and another onthe flat panel area next to the damaged corrugation. A reference line has been extended between the two spacers ithe two round objects just below the inspector’ hands; each spacer has a proteuding vertical pin to hold the reference line over the corrugations) The inspector is measuring the distance from reference line to the surface of the undamaged corrugation to establish a reference plane See Section 4.6.4 November 2003 45. Specific andl Unusual CasesMeasuring downward damage on a standing roof corrugation lend at roof ends, Step #2: the inspector measures the distance from reference line to point of downward maximum deflec tion. To calculate the depth of damage, the frst measurement is subtracted from the second measurement ‘See Section 4.6.4 made in Step made in Step 4.6.5. Measuring Upward Damage on the Panel Area Between Corrugations ‘When measuring upward damage to roofs, roof camber {curvature} should be ignored, as has been recommend ed above in Sections 2.1.2.2 and 4.6.1 above. In this case, the measurements are made from within the con tainer. The reference line should be extended across the roof width from just inside the top side rails on either side of the damage, and dent depth measured from the November 2003 46 Specific and Unusual Cases reference line to the point of maximum upward deflec tion, Figure 4.16 below illustrates this method. Fig. 4.16/Measuring upward damage on roof panels between corrugations. See Section 4.6.5. 4.6.6 Measuring Upward Damage Within Corrugations; Upward Bows to Roof Sheets; and Upward Damage to Header Extension Plates Because an upward dent within a standing corrugation will reach the IICL criterion of ISO plus 10 mm (3/8 in) limit before it reaches the 35 mm (1-3/8 in) limit for dents, the ISO plus HCL limit governs for this type of damage. Upward bowing of the roof sheet (without an accompanying dent or bend) and upward header exten- sion plate damage of any kind are also subject to the ISO plus IICL criterion. Therefore, all three conditions are measured by the same basic technique. To provide a simplified and standardized method of determining whether the types of damage to corrugated roofs described above exceed ISO plus IICL tolerances, this Guide has devised a method similar to that recom: mended for side and front panel damage in Sections 2.2.2 and 4.4.3. Damage is compared to a set refer ence dimension that includes ISO plus HCL tolerances. For the purposes of determining if upward roof damage exceeds IICUs limit of ISO plus 10 mm (3/8 in), HCL has set a relerence plane 38 mm (1-1/2 in) above the upper surfaces of the top side rails, Therefore, if damage November 2003 47 Specific and Unusual Cases‘extends into or beyond the 38 mm (1-1/2 in) limit above the upper surfaces of the top side rails, it exceeds ISO plus IICL tolerances and requires repair. To measure the damage, 38 mm (1-1/2 in) spacers are placed on the top surfaces of the top side rails on either side of the damaged area. reference line is positioned actoss the spacers and over the point of maximum Upward deflection of roof or header extension plate. lf the damage actually touches the reference line, it can be assumed that it has reached (ie,, extended into or beyond) the 38 mm (1-1/2 in) limit, and therefore requires repair. This method is illustrated in Figure 4.17. 1 38 mm (1-1/2 in) spacers are not available, any spac crs of greater length can be used, and the “space ‘ouvmeasure back” method used to check if the damage exceeds 38 mm (1-1/2 in) ete create emer Fig. 4.17/Measuring upward damage within roof comugation. See Section 4.6.6 4.6.7. Measuring Downward Bows to Roof Sheets and Downward Damage to Header Extension Plates ‘A downward bow of the roof sheet, (without an accom- panying dent or bend} and any type of downward damage to a header extension plate are subject to the ICL criterion limiting cube intrusion to 50 mm (2 in). tn these cases, the upper surface of the container cube is defined by the plane formed by upper surfaces of the top side rails on the container interior. Measurements are made from inside the container. Tivo different measur- ing methods are used, depending on the type of top ral 4.6.7.1 Measuring Downward Bows to Roof Sheets and Downward Damage to Header Extension Plates: Tubular Top Rails If the top ral is tubular, a reference line is positioned at the bottom edge of the top rail and extended across the ‘width of the container under the point of maximum «downward deflection of the roof to the bottom edge of the opposite top rail. A measurement is made from the reference line to the lowest point of the roof. To calcu- late the intrusion into the cube, this measurement is, subtracted from the height of the top side rail. If the intrusion exceeds 50 mm (2 in), repair is required, Figure 4.18 illustrates this method ROOF PANELS - WITH TUBULAR TOP SIDE RAILS — ror soe nat \ \. pm TT eee LIL UE Fig, 4.18/Measuring downward bow of roof sheet (ubular rail), See Section 4.6.7.1 November 2003 48 Specific and Unusual Cases November 2003 49—_Specitic and! Unusual Cases4.6.7.2. Measuring Downward Bows to Roof Sheets and Downward Damage to Header Extension Plates: Flat-Bar Top Rails Hi the top ral isa flat-bar type, a reference line is spaced downward from the top surface of the side rails 50 mm (2 in). If the roof sheet touches the reference line, repair is required. Figure 4.19 illustrates this method [ROOF PANELS - WITH FLAT BAR-TYPE TOP SIDE RAILS |-OGNAL ROOF POSTION TOP - 4.20/Measuring floor gouge for depth only, using a gouge Soivice g a) 8 3 fercaalee et feio 4 s3hal Ee 3} 3 ¢ i =| 2 a gs, 3 Fig, 4.19/Mcasuring downward bow of roof sheet fT mn {latcar rail). See Section 4.6.7.2. 4.7. Measuring Damage to Floors HICL has two inspection criteria for floor gouges. One: sets limits for gouge depth only, and the other limits both depth and width, 4.7.1. Measuring Gouges for Depth Only In the first case, a straight-edge is placed horizontally on edge across the gouge to establish the position of the undamaged floor surface. scale or ruler is used to measure the distance from the straight-edge to the bot tom of the gouge. The same basic approach is used to measure height differences between planks. This method is shown in Figure 4.21 opposite. Alternatively, the inspector can use a type of scale with 2.15 mm (5/8 in) protrusion, as shown in Figure 4.20 opposite. If the protrusion does not touch the bottom of the gouge, repair is required. November 2003 50. Specific and Unusual Cases Fe Fig, 4.21/Measuring floor gouge for depth only, using a straight-edge and a scale (ruler). See Section 4.7.1 November 2003 51 Specific and Unusual Cases4.7.2. Measuring Gouges for Depth and Width In order to be considered repairworthy, the gouge must bbe more than 5 mm (3/16 in) deep over the entire width of at least 150 mm (6 in}. It does not require repair if coy a single location exceeds 5 mm (3/16 in) in depth within the 150 mm (6 in} width, Note that the width of the gouge is defined as its narrower dimension, and the length as the larger dimension. That is, the width is not related to the orientation of the gouge relative to the container. See Figure 4.22 for an illustration of this ri terion. ig. 4.22/llustration of 1ICL inspection criteria for floor gouge. See Section 4.7.2 November 2003 52 Specific and Unusual Cases, 7.2.1 Measuring Depth and Width of Gouges with a Straight-Edge and Simple Scale or Ruler To determine if a gouge exceeds the damage limits for depth and width, the gouge must first be measured to see if its width exceeds 150 mm (6 in). If it does, a straight-edge is placed across the gouge at its deepest point where the width equals or exceeds 150 mm (6 in) ‘The bottom surface of the straight-edge establishes the reference line or plane for the undamaged floor surface. Ascale or ruler is used to measure the distance from the bottom edge of the straight-edge to the bottom of the gouge. If at any point in the gouge an area is found where the depth exceeds 5 mm (3/16 in) over the entire 150 mm (6 in) width, then the gouge must be repaired. Figure 4.23 illustrates this method. Loon aoues semiourenae Fig. 4.23/Measuring floor gouge for depth and width, using a straightedge and a scale (ruler). See Section 4721 November 2003 53. Specific and Unusual Cases4.7.2.2. Measuring Depth and Width of Gouges with a Special Gouge Scale The depth and width of a gouge can also be measured using a special scale that is designed with a 150 mm (6 in) by 5 mm (3/16 in) protrusion on one side, The scale is placed across the gouge with the protrusion face down in the gouge and perpendicular to the gouge length. If the ends of the scale beyond the protrusion on either side rest firmly on the undamaged floor sur- faces on either side of the gouge, the gouge must be repaired. IF the ends of the scale on either side of the gouge do not touch the floor (ce, if there is space between the bottom edges of the scale and the undam- aged floor), the gouge does not require repair. This method is illustrated in Figure 4.24, f Sraneeone repanis eau.) 4.8 Measuring Damage to Understructure Most damage to understructure can be measured using the standard methods described in Section 2. Variations in this method are explained in the subsections below, and are illustrated in Figures 4.25 - 4.30. Since IICL criteria do not require repair of damaged bot tom flanges that are not cut or tom, most damage measurements involve the crossmember web. / Segumpsasoes Fig. 4.24/Measuring floor gouge for depth and width, using a special scale (ruler). See Section 4.7.2.2. November 2003 54 Specific and Unusual Cases ay Fig. 4.25/Measuring damage to crossmember web when impacted directly. See Section 4.8.1 November 2003 Specitic and Unusual Cases4.8.1. Measuring a Direct Impact to a Crossmember Web Figure 4.25 shows a common type of crossmember web damage in which the web has been damaged by a direct impact. In this case, a reference line is extended over the crossmember from one side rail to the other, ‘outside the points of attachment of the formed edge between web and flange. The distance between the ref erence line and the point of maximum deflection is measured to determine if the web requires repair. Figure 4.25 on page 55 and the photos on page opposite illustrate this method. November 2003 56 Specific and Unusual Cases ‘Measuring direct impact to crossmember web: the inspector rmeasutes the distance from reference line to point of maxi ‘mum deflection in the web. Note thatthe reference line extends across the full width ofthe crossmembser along the formed edge between web and flange, See Section 4.8.1 ‘Measuring direct impact to crossmember web as in the photo ‘on the top ofthe page, the inspector has extended the refer tence line along the full width ofthe crossmember from rail to rail, and is measuring the distance from reference line to max ‘mum point of the web deflection. See Section 4.8.1 November 2003 Specific and Unusual Cases4.8.2 Measuring an Impact to a Crossmember Web from the Flange Side Figure 4.26 shows another common type of crossmem- ber web damage. In this case, the web has received an impact from the flange side of the crossmember. The reference line is extended from one side rail to the other along the inside radius of the crossmember where the ‘web meets the flange, as shown in Figure 4.26. A meas- ‘urement is then made from the reference line to the point of maximum deflection in the web. This is the preferred method of measurement. 4.8.3. Measuring Crossmember Web Damage at the Web Center In some case, damage occurs at the center of a cross member web. Figure 4.27 shows how this type of damage should be measured. The reference line is, extended along the web surface along the entire length fof the crossmember. A measurement is mace from the reference line to the point of maximum deflection in the web, ‘ee rou nce st. net LA Pesci ropg UA Fig, 4.26/Measuring damage to crossmember web when flange side has been impacted. See Section 4.8.2 November 200358 Specific and Unusual Cases Uunpensraucrune Fig. 4.27/Measuring damage to center of crossmember web, See Section 4.8.3 November 2003 59. Specific and Unusual Cases4.8.4 Measuring Crossmembers Bent in Two Locations There are some situations in which the reference line cannot be placed directly on the crossmember, This is the case when the same crossmember is damaged in two locations, such as when (1) both web side and flange side have been damaged, or 2) the flange has been pushed upward against the web so that a reference line cannot be positioned on the inside formed edge where web meets flange. In these cases, the “space out/measure back” method should be used, as shown in Figure 4.28, eros Fig, 4.28/Measuring damage to crossmember when bent in to locations (web and flange sides). See Section 484, November 2003 60 Specific and Unusual Cases 4.8.5 Separation of Crossmembers from Underside of Floor Ifthe top flange of a crossmember is pulled away from the underside of the floor, measure the separation as fol- lows 4.8.5.1 Mark the web at each floor sere location. 4.85.2 Insert a taper gauge into the separation at each mark, oor measure with a scale as shown in Figure 4.29, Do not insert gauge at other locations 4.8.5.3 Measure the width of the gauge at the point where it just emerges from the outer surface of the web. If this distance is greater than 10 mm (3/8 in), repair is required Note that the width of the taper gauge is not meas- ured at the shank of the screw, but rather at the outer web surface. Also, do not measure at any location along the crossmember other than the locations of floor serews. — crossensen mares wee Fig, 4.29/Measuring separation of crossmember flange from floor (at point on flange adjacent to formed radius). See Section 4.8.5, November 2003 61 Specific and Unusual Cases4.8.6. Crossmembers Outside ISO plus IICL Tolerances Generally, the bottom surfaces of the lower crossmem- ber flange is at or near the lowest permissible height allowed in the ISO standards. Since IICL allows an additional tolerance of 10 mm (3/8 in), measure any downward deflection of lower crossmember flanges as follows 4.86.1 Run a reference line inside the erossmember at the top surface of the lower flange from one side rail to the other. 48.6.2 ‘Measure the distance from the line to the lowest point of the top surface of the lower flange. IF this distance is greater than 10 mm (3/8 in), repair is required. See Figure 4.30, November 2003 62 Specific and! Unusual Cases UnoenstAUCTURE co Tome Fig, 4.30/Measuring crossmember damage to determine if ISO + HICL tolerances are exceeded. See Section 4.8.3 November 2003 63 Specific and Unusual CasesSECTION 5 GLOSSARY OF DAMAGE MEASUREMENT TERMS. Bow: graclual (not abrupt) deformation of the entire length of the component in a direction perpendicular to that length, Concave damage: Damage whose middle portion extends away from a reference point (shaped like the inside surface of a sphere), Convex damage: Damage whose middle portion extends towards a reference point (shaped like the outside surface of a sphere) NOTE: The same damage may be either concave or convex, depending on which point of reference is chosen Example: A side panel bow that intrudes into the ube of the container is concave when viewed from a reference point outside the container and convex when viewed from a reference point inside the container. Deflection: Change in position of a component from its original profile due to damage or other structural stress Depth of damage: Amount of deflection in any direc- tion (in mm or other linear measure) away from the original, undamaged profile Envelope: the outermost planes of all container surface dimensions as defined by the International Organization for Standardization (1SO), including any tolerances to those dimensions permitted by ISO standards, plus (in this manual) those permitted according to HICL criteria Original, undamaged profile: The position of all points ‘of the container as defined in either the design drawings ‘or the prototype of a brand-new container. November 200364 Glossary of Terms Qut-of80: Deflections that place a component beyond the envelope as defined above. Reference dimension: an assumed dimension that defines the limit of damage that does not require repair. A reference dimension is defined when a damage meas turement may not be directly compared to a limit defined in IICL cri Reference line: a string or other physical line from which dimensions are directly measured. Depending oon the circumstances, depth of damage may be obtained from direct measurement from a reference line, or by calculation based on measurement taken from the reference line (see “space ouvmeasure back method” below, Space out/measure back method: @ method for measur ing damage by placing the reference line beyond the limit of damage according to ICL criteria, measuring the maximum depth of damage to that line, and calculating the true amount of damage based on the position of the reference line. (See Section 2.1.2 for a fuller ‘explanation, Spacer: a shim or small thick object that may be attached to a container surface and on which a refer- ence line may be placed to be ofiset from that surface. November 200365 Glossary of TermsList of Members Amphibious Container Leasing Limited Carlisle Leasing International, LLC Container Applications International, Inc. Cronos Containers Limited Flexi-Van Leasing, Inc. Florens Container Services (U.S.) Ltd. GE SeaCo SRL Gold Container Corporation Interpool, Inc. Textainer Equipment Management (U.S.) Ltd. Trac Lease, Inc Transamerica Leasing Inc. Triton Container International Ltd,