GL for Container

8/12/2019 GL for Container

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Rules for Classification and Construction

VI Additional Rules and Guidelines

1 Container Technology

1 Guidelines for the Construct ion, Repair and Testing of Freight Containers

Edition 1995


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The following Guidelines come into force on Apri l 1st, 1995

Germanischer Lloyd Aktiengesellschaft

Head OfficeVorsetzen 35, 20459 Hamburg, Germany

Phone: +49 40 36149-0Fax: +49 40 36149-200

[email protected]

www.gl-group.com

"General Terms and Conditions" of the respective latest edition will be applicable(see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys).

Reproduction by printing or photostatic means is only permissible with the consent ofGermanischer Lloyd Aktiengesellschaft.

Published by: Germanischer Lloyd Aktiengesellschaft, HamburgPrinted by: Gebrder Braasch GmbH, Hamburg


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Table of Contents Chapter 1Page 3

Table of Contents

Section 1 General Instructions and Guidance

A. General Test Conditions .............................................................................................................. 1- 1

B. Types of tests .............................................................................................................................. 1- 2

C. Construction characteristics (design principles) .......................................................................... 1- 5

D. Materials ..................................................................................................................................... 1- 7

E. Jointing methods ......................................................................................................................... 1- 11

F. Marking and documentation ........................................................................................................ 1- 14

Section 2 Requirements and Tests

A. General Requirements ................................................................................................................. 2- 1

B. Tests ............................................................................................................................................ 2- 1

Section 3 Thermal Containers

A. General requirements .................................................................................................................. 3- 1

B. Refrigerating and/or heating appliances for thermal containers .................................................. 3- 5

Section 4 Repairing of Containers

A. Guidelines for the Authorization of Container Repair Workshops ............................................. 4- 1

Section 5 Special Containers for use on Seagoing Ships and Offshore Installations

A. General ........................................................................................................................................ 5- 1

B. Structural fire protection ............................................................................................................. 5- 1

C. Special containers, electrical equipment ..................................................................................... 5- 2

Section 6 Tank Containers

A. Definition .................................................................................................................................... 6- 1

Anne x A

Annex B

A. Stamp .......................................................................................................................................... B- 1

B. Label ........................................................................................................................................... B- 1

C. Specimens ................................................................................................................................... B- 3

Annex C


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Section 1 General Instructions and Guidance Chapter 1Page 1 1

A

Section 1

General Instructions and Guidance

A. General Test Conditions

1. Scope

1.1 These Regulations apply to freight containersand their built-in or built-on refrigerating, heating,filling, emptying, and safety equipment.

1.1.1 These Regulations also apply correspondinglyto other freight containers, such as swap bodies andspecial containers for use on offshore installations.

1.2 Containers within the scope of these regula-tions are freight containers that can be used repeatedlyand which are

of open or closed, box- or tank-like or platform-based design,

of a durable nature and so resistant as to with-stand all loads to be expected during transporta-tion,

provided with equipment permitting their easyhandling, in particular during their transfer fromone means of transportation to another.

1.3 These Regulations refer both to the buildingand testing of new containers and to the testing of usedcontainers and their repair.

1.4 Containers that do not fully correspond to thedefinition given in 1.2 or which are subject to specialconditions of use may be tested in general accordancewith these Regulations and/or in accordance with anagreed specification.

2. Rules and standards also applicable

2.1 For the construction of containers with alltheir equipment, the following rules are to be appliedcorrespondingly:

I Ship Technology, Part 1, Chapter 2 - "MachineryInstallations" of Section 1 "General Rules and Instruc-tions ", Chapter 3 - Rules for the Construction of Electrical Installations, Chapter 4, Section 2 - Rulesfor the Construction of Refrigerating Installations, and

II - Materials and Welding Technology, Parts 1, 2 and3.

2.2 Reference is made to the international con-tainer standards, especially ISO 1496 "Series 1 FreightContainers - Specification and Testing" and to thecorresponding EN standards for swap bodies.

2.3 The conditions for approval of containersaccording to the Convention for Safe Containers(CSC) of December 2nd, 1972 are, in principle, ful-filled if the containers are constructed and tested inaccordance with these regulations.

2.4 The national and/or international rules as maybe applicable are to be complied with where the trans-portation of dangerous goods in containers is con-cerned.

3. Testing procedure

3.1 Container testing by the Society normallycovers the design documents, trials, and production(for types of tests, see B.).

3.2 A certificate is issued by the Society (HeadOffice or the competent Surveyor) on the results of thetests. Depending on the type of container and testconcerned, plates, steel-die stampings and labels serveas test evidence on the container itself (see F-markingand Documentation).

4. Works approvals

4.1 Works where containers or ancillary partsintended for them are manufactured or where contain-ers are repaired must be qualified in respect of shopfacilities, quality control, production methods andworkmanship for the work to be carried out. Qualifi-cation is certified to the works in the form of an ap-proval.
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Section 1 General Instructions and Guidance VI - Part 1

B

4.2 General representation of the process of container testing

Order

Plan approval

Head Office (HO)

workshopinspection Type test

HO or surveyor HO or surveyor

Supervision of production

Surveyor

ApprovalCertificate

HO

TypeCertificate

HO

AcceptanceCertificate

&Completion Note

Surveyor

Certificationby Surveyor

Supervision on constructionin accordance with specification

[Owners Inspection]

depending on order

ContainerCertificate

HO / EDP

4.3 The application for approval to be made bythe works shall contain particulars of the scope of production, organization, technical facilities and pro-duction methods as well as of the qualifications of theworking staff including supervisors (cf. GL Rules forWelding, Annex A). Approval may be granted fol-

lowing scrutiny of the application and inspection.

4.4 The validity period of an approval granted inaccordance with these Rules is 3 years. If work isregularly performed under the Societys supervisionduring the validity of the approval, the validity periodmay be extended on application by 3 years at a timewithout further checking.

4.5 If no work has been performed under theSocietys supervision for more than one year, the ap-proval may be granted anew on expiry of its validityperiod only if the conditions for doing so continue toexist and this is demonstrated during a further worksinspection. The approval may then again be grantedfor a validity period of 3 years.

4.6 The Society is to be informed about anychanges in works facilities, in production methods orin the composition and qualification of the staff whichaffect the conditions for approval.

4.7 With regard to qualification and approval in

respect of welding practice, see also E.1 .

B. Types of tests

1. Examination of design and constructiondocuments

1.1 The documents required for examination areto be submitted in triplicate to the Societys Head Of-fice in good time before the commencement of pro-

duction and testing.

1.2 The documents to be sent in for examinationshall comprise:
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a) Drawings showing the arrangement, dimensions,and materials of the structural components of thecontainer;

b) Particulars of jointing methods (welding) and

connections envisaged;c) Particulars of the origin of important ancillary

parts (such as fittings, bottom and wall ele-ments);

d) Proof calculations insofar as customary or nec-essary for the type of container concerned;

e) For thermal containers, additional documents inaccordance with Section 3, A.2 ;

f) For CSC approval, additional documents de-pending on the competent approving authority.

1.3 The examined documents are sent, markedwith the Societys inspection stamp, to:

the manufacturer

the competent GL Inspection Office

the relevant approving authority, if necessary.

The modifications to be effected or the guidance to becomplied with are notified by being entered in theexamined documents and/or the Society's coveringletter. The drawings must be clearly assigned to thetype of container to be tested so that they may serve assupporting documents for the Surveyor when carryingout the test and issuing certificates.

1.4 Where other testing bodies are involved, thedocuments shall be submitted in a number to be agreedon beforehand.

2. Type tests

2.1 The "type test" following the examination of the documents serves to furnish proof that the con-tainer type complies with the requirements in respectof mechanical strength and function. The necessarytests are described in Sections 2 and 3 and are carriedout in the presence of a GL surveyor.

2.2 A report of the type test will be prepared; if the results are satisfactory, a certificate will be issued(cf. F. .). A printed form issued by the Society is to beused for the test report.

2.3 The type tests may be carried out at differenttimes and frequencies. The Society differentiates asfollows:

2.3.1 The Prototype Test is the initial test of anovelty or a greatly modified design. The container isgenerally fabricated as a single item. However, evi-

dence of the materials used must be at hand and theconstruction and materials must correspond to those of the planned series.

2.3.2 The Type Test serves to furnish the proof mentioned in 2.1 , especially in cases where designmodifications are put into effect subsequent to theprototype test (2.3.1). The container to be tested mustbe a product from the series concerned and should betaken from the first ten containers.

The Society reserves the right to recognize the proto-type test as a type test, provided that no substantialmodifications have been made.

2.3.3 Repeat Type Tests are a repetition of thetype test and may become necessary in the case of

large construction series, reorganisation of fabricationor extended interruptions in the fabrication of a series.

Repeat type tests will be stipulated on a case-by-casebasis.

3. In-production tests

3.1 Supervision of production

In order to check the conformity of the containers of aseries with the container tested in conformity with 2.,the Society carries out the supervision of productionthrough its Surveyors. The frequency of the checksdepends on the requirements the containers are subjectto and on the nature of the test order.

The type of supervision is indicated on the certificatesissued and on the individual containers; cf. F. .

3.2 In order to furnish evidence of the construc-tion remaining uniform within the series, the Society'sSurveyor shall be given access to the records of the in-plant quality control system.

3.3 Apart from the checks in accordance with 3.2,repeat tests may be necessary as strength and opera-tional tests . The nature and frequency of these testsdepend on the container type, the cargo to be trans-ported, and the number of containers in the series;further particulars hereon are contained in Sections 2and 3.

4. Testing of impregnations and coatings

4.1 Impregnations

4.1.1 Upon application, the Society will test forcompliance with impregnation specifications issued bycertain authorities such as the Australian Quarantineand Inspection Service (protection against infestation).
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The test specimens are selected at random by the Sur-veyor and shall be unambiguously marked (GL testspecimen stamp). The test specimens shall, if possible,be cut in such a way that their volumes can be calcu-lated.

4.1.2 The test specimens are to be sent to the Soci-etys Head Office together with a list containing thefollowing details:

Serial test specimen number

Lot or batch number

Brief designation of the structural component(roof, end or side walls, bottom)

Supplier of the structural component

Recipient (container manufacturer)

Designation of the impregnating agent

Sampling date.

The test specimen need bear only the serial test speci-men number, the sampling date and the GL test speci-men stamp.

4.1.3 In order to reduce the testing expenditure,documents furnished by the manufacturer, in particularcertificates issued by independent institutions, may berecognized. It must be possible to associate the docu-ments with the lots or batches supplied.

4.1.4 The test results concerning satisfactory im-pregnation will be confirmed in the certificates.

4.2 Coatings

The testing of the structure of a coat of paint or othersurface treatment and the associated preparatory works(sandblasting etc.) during the production of containersor on used containers necessitates a special order to theSociety and will be carried out only by arrangement.

5. Testing of suitability for certain cargoes

5.1 To ascertain the suitability of a container forbeing loaded with a sensitive, aggressive or otherwiseunusual cargo, e.g. in respect of tightness, cleanliness,insulation, refrigerating machinery or other equipmentas well as construction in general, the Society carriesout surveys upon special request (e.g. "butter test").

5.2 Where the loading of such cargo is subject tothe approval procedure of an official authority, theapplication for testing is to be routed via this authority.

6. Testing of used containers

6.1 Testing to ascertain the state of conserva-tion

6.1.1 Individual containers, parts of series or seriesof containers may be checked by the Society for theirstate of conservation and operational safety and reli-ability within the scope of existing rules (e.g. CSC).

6.1.2 Apart from a close visual inspection (espe-cially of the base structure), testing may also includeload and operational tests. The selection of the con-tainers to be tested (in the case of random tests) andthe frequency of the tests are to be agreed upon in each

individual case while having regard to the containertype, their age, and the number of containers in theseries.

6.1.3 The Society may, by special arrangement,carry out the regular supervision of the condition of containers (series), e.g. in conjunction with repairsupervision in accordance with 6.3.

6.2 Testing for certificate renewal

In the case of containers where the validity of thecertificate depends on repeat tests at certain intervals,e.g. on hydrostatic pressure tests where tank containersare concerned, testing shall be carried out in the pres-ence of a GL Surveyor.

6.3 Testing of repairs

6.3.1 A GL Surveyor may be called in to establishand assess a case of damage as well as to test a con-tainer upon completion of a repair.

6.3.2 In the case of heavy damage to tank contain-ers, where the validity of the certificate depends ontheir safe condition, the Society's Head Office shall beinformed. Repair drawings showing arrangement,dimensions and materials shall be submitted to HeadOffice. A Surveyor shall be called in to supervise thenecessary tests prior to re-commissioning the con-tainer.

6.3.3 The Society monitors the quality of container

repairs in shops inspected and authorized by it. Thissupervision of repair standards is carried out at randomand is independent of surveys of individual containersin accordance with 6.3.1 and 6.3.2 (cf. Section 4. ).
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C. Construction characteristics (design prin-ciples)

1. General

The principles mentioned hereafter apply to freightcontainers and, where applicable, to swap bodies of allsizes and types. They are essentially in agreement withthe relevant standards (ISO and EN).

2. Dimensions, weights, tolerances

2.1 The tables given in Annex A show the maindimensions, total weights and most important toler-ances of the containers standardized by ISO 1496(Series 1). References to possible deviations in con-nection with individual types of construction are con-tained to the necessary extent in Section 2 under "De-sign Requirements".

2.2 The maximum permissible gross weightsindicated in Annex A are maximum weights laid downby standardization. In keeping with normal practice,gross, net and tare weights are defined as follows:

R P T= +

where

R is the maximum permissible gross weight of the container including cargo,

P is the maximum permissible payload (maxi-mum net weight) and

T is the weight of the empty container or theaverage tare weight of a container series.

Equipment parts (such as lashing elements,refrigerating equipment) normally remainingattached to the container even when trans-ported empty are included in T.

2.3 The laying down of an (ISO) gross weightrating for a container or a container series does notpreclude prototypes or certain containers of a series oreven certain structural components of containers frombeing designed and tested for higher maximum per-missible gross weights.

2.4 Details of dimensions and weights on thecontainers and in certificates shall be harmonized withthe specification concerned and, if possible, standard-ized within any one constructional series. Where majorweight deviations cannot be avoided owing to theconstruction, the manner of marking and the docu-mentation are to be specially agreed upon. In the caseof tank containers it may be advisable, depending onthe cargo, to ascertain and document the individualdeadweight.

2.5 No parts projecting beyond the rated externaldimensions (length, width, height) of the container areto be permanently attached to it.

3. Construction

3.1 Main elements

3.1.1 A container consists, as a rule, of a baseframe and a roof frame connected to each other bycorner posts.

3.1.2 The corner structure serving as a support fortransportation, for lifting and clamping purposes andas a platform for stacking may be constructed as partof the corner post or as an independent structural ele-ment connected in a positive way with the corner post.

3.1.3 Bottom, walls, doors, and roof as far as pro-vided are laid or hung in the framework and welded,bolted, riveted, screwed or glued to the latter, depend-ing on the material and construction used. Stiffenersmay be provided to absorb loads acting at right anglesto the surfaces unless the plating is capable of doingso.

3.2 Design details

3.2.1 Corner posts and corner fittings

3.2.1.1 The corner posts shall feature a sufficientplate thickness or be reinforced by corrugations orother stiffening means in such a way that the compres-sive and bending stresses resulting from the stackingload can be safely absorbed without buckling.

The corner post must be connected to the corner fit-tings over its full cross section, either a sufficient pro-

jection length of the corner fittings with respect to thecorner post flanks being chosen or an adequate weld-ing joint being ensured by chamfering (single bevelbutt joint). (See also Section 1, E.1.5 ).

3.2.1.2 Such materials and dimensions shall be cho-sen for the corner structures (corner fittings) that thehigh, even shocklike operating loads are safely ab-sorbed.

Cast corner fittings corresponding to internationalstandards are shown in Annex A (Figs. A.1 and A.2).

Welded corner and securing fittings shall conform tothe standards currently in force with regard to strengthand dimensions. The chosen method of welding exe-cution shall ensure that no crevice corrosion can occur.Methods of welding execution require the approval of the Society. The quality assurance procedure shall beagreed with the Society.

The projection length of the corner fittings with regardto the roof and base structures shall equal:
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11 mm 17,5 mm relative to the lowest point of thebase structure including the endtransverse members but exclu-sive of the bottom side rails. Inrespect of the bottom side rails,a 4 mm projection length shouldremain.

6 mm relative to the uppermost pointof the roof including the top siderails and any screw or rivetheads.

3.2.2 Base structure

3.2.2.1 The bottom corner fittings shall be capable of bearing and transmitting, by themselves, all loads inthe container.

3.2.2.2 Cross members and floor plates or planksshall withstand the loads due to cargo and vehicles(fork lift trucks). When dimensioning a wooden floor,in particular a plank floor, due regard shall be paid tothe frequently repeated (wheel) loads with regard tothe fact that the bearing strength of the wood does notremain constant and to the possible variation of thewood quality.

3.2.2.3 No part of the base structure shall deflectmore than 6 mm below the lower support surfaces of the bottom corner fittings under a dynamic load or acorresponding static load (1.8 R) acting uniformly onthe floor (cf. Section 2, A.2.2 ).

The base structure shall resist all forces, especiallytransverse forces, which arise from the cargo in serv-ice.

3.2.2.4 The base shall be tight against transient un-derflooding and sufficiently protected against corro-sion and rot. Gaps between metal parts and woodenflooring, especially at the ends of wooden members,shall be filled with a suitable sealing compound whichdoes not become brittle.

3.2.2.5 In view of the high level of wear, it is rec-ommended to reinforce or cover the floor (with anentrance plate) in the vicinity of the door.

3.2.2.6 Reinforcements shall be provided in the areaof the recess for semitrailers (gooseneck tunnel) toabsorb the wheel loads and cargo pressure. As a rule,these reinforcements shall consist of longitudinal andtransverse tunnel members with further reinforcementbeing brought about by constructing the tunnel roof asa load-bearing membrane.

The standardized dimensions of the gooseneck tunnelare shown in Fig. A.3 of Annex A.

3.2.2.7 If cut-outs for fork lift pockets or otheropenings are provided in the bottom side rails, ade-

quate overlapping of the reinforcing plates shall beensured.

The standardized dimensions and spacings of fork liftpockets are shown in Fig. A.4 of Annex A.

3.2.2.8 If lifting edges are provided on the bottomside rails, they shall be constructed to the standardrepresented by Fig. A.5 of Annex A.

3.2.2.9 With regard to the local stressing of the bot-tom side rails by shunting shocks during transportationby rail, the connections of the bottom side rails to thecorner fittings shall be made with special care and,where necessary, be reinforced or stiffened.

3.2.2.10 In order to prevent the base structure andtransverse members of the container on the one hand

and the longitudinal members of the vehicle on theother from being stressed too much during road trans-portation, there shall be provided either

sufficient contact surface according to Fig. A.6in Annex A or

a sufficient number of adequately strong trans-verse members which, however, may projectrelative to the other transverse members.

The prescribed number and spacings of thesetransverse members are shown in Figs. A.7 andA.15 of Annex A.

The maximum load to be transmitted by thesupport areas shall not exceed the value 2 R in-cluding the augmentation for dynamic loadcases.

The contact surfaces of a smooth base structureor the bottom faces of those transverse membersforming part of a base structure and serving forload transfer to a vehicle shall lie in a plane, thedesign distance of which from the bottom facesof the corner fittings shall amount to between 11mm and 17.5 mm in accordance with 3.2.1.2.

3.2.3 Roof 3.2.3.1 Roofs shall be shaped in such a way that aslittle water as possible may collect on them. Camber-ing is recommended.

Where roofs are to be capable of supporting not onlypersons but also cargo, attention shall expressly bedrawn to this fact, giving details of the surface pres-sure to be expected, and a corresponding test shall beconducted.

3.2.3.2 In the area of corner fittings, reinforcementssuch as laminations of at least 4 mm thickness shall beprovided in such a way that the roofing will still beprotected with the spreaders offset by 200 mm intransverse direction and by 225 mm in longitudinaldirection.
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3.2.3.3 The support frames for tarpaulins coveringopen-top containers shall be so designed or dimen-sioned as to ensure a positive connection between thetop side rails (cf. Section 2, B.2.6 ).

3.2.3.4 It must be possible so to clamp and securedetachable roof elements as to preclude any incorrecthandling and/or to permit the condition of the meansof clamping and securing to be visually checked fromthe ground (outside) even if the container is on a rail-way wagon.

3.2.4 Walls

3.2.4.1 Wall elements shall be so connected witheach other and with the surrounding frames that

strength, dimensional stability and weatherproofnessare sufficiently maintained under the repeated loads tobe expected (see also E. , jointing methods).

3.2.4.2 Hinged or detachable walls or wall sectionsshall be so clamped and secured as to preclude anyincorrect handling and/or to permit the condition of theclamps and securements to be visually checked fromthe ground (outside).

3.2.5 Doors, flaps and manholes

3.2.5.1 Doors, flaps and manholes form part of thesurrounding structural elements such as walls, roofs,bottoms, tank shells, etc. In certain cases they replacethese structural elements, e.g. the double-leaf door of ageneral cargo container replaces an end wall. As aconsequence, doors, flaps and manholes as well astheir locking elements are required to withstand allloads that the associated structural elements are subjectto according to Section 2 .

3.2.5.2 If flaps or manhole covers cannot be posi-

tively fitted into the surrounding structural element,the opening shall be stiffened as necessary.

3.2.5.3 The necessary seals shall be robust, flexibleand durable; they shall not become brittle even underheavy solar irradiation and shall be resistant to thecargo to be carried.

3.2.6 Other guidance

A sufficient number of suitable lashings shall in gen-eral be provided in the container in order to secure thecargo against displacement due to the state of the seaor due to inclinations attributable to other sources. Theconstruction and extent of these appliances are subjectto the conditions imposed by the user.

D. Materials

1. General guidance

1.1 Only materials with guaranteed properties(strength; low-temperature toughness where applica-ble; bending properties; weldability; resistance tocorrosion and/or rot; etc.) are to be used for all load-bearing components of containers as well as for tanks,piping, valves and fittings of containers intended forliquid or gaseous cargo. Unless otherwise providedhereinafter or unless special arrangements have beenmade, the Societys Rules for Materials 1, recognizedstandards (e.g. DIN EN 10025) or other equivalentstandards shall be taken as a basis in this respect. Asregards tank containers intended for the transportationof dangerous goods, the respective legal provisionsshall additionally be complied with.

1.2 In general, only materials which have beenmade by manufacturers approved by the Society maybe used. Approval is granted in accordance with theSocietys Rules; application for approval is to be madeto the Societys Head Office. Upon application, theSociety may recognize approvals granted by neutralother testing authorities or grant approval on the basisof regular tests of the products.

1.3 Unless otherwise required hereinafter, the

materials shall be covered at least by works test cer-tificates conforming, at present, to EN 10204. 3.1 C(GL) acceptance test certificates conforming to EN10204 shall be produced for cast steel as well as formaterials intended for containers for dangerous goods.In special cases or at the explicit request of the pur-chaser, check tests of the actual material supplied shallbe carried out under the Societys supervision. Allmaterials and structural components shall be marked insuch a way that an unambiguous identification of themanufacturing mill or plant, the material grade and theheat or batch is possible. With regard to the marking of

castings, see 2.2.9 .

1.4 Thermal containers shall in addition complywith the requirements according to Section 3, A.3.1.1 .

1 Rules for Classification and Construction II, Materials and

Welding Technology, Part 1 - Metallic Materials.


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2. Steel materials

2.1 Rolled steels

2.1.1 Ordinary and higher strength hull structuralsteels satisfying the Societys Rules for Materials aswell as weldable structural steels, e.g. conforming toDIN EN 10025, or pipe materials, e.g. conforming toDIN 1626, DIN 1629, may be used for the componentsmentioned in 1.1. Other equivalent structural steelswith a minimum yield point of 235 N/mm 2 may beused with the Societys consent. The requirements forspecial steels (such as weather-resistant structuralsteels, steels tough at subzero temperatures or high-strength steels with minimum yield points above 355N/mm 2) will be laid down from case to case.

2.1.2 Structural steels showing, apart from suffi-cient strength, the properties required for the respec-tive application (e.g. good bending properties,weldability) shall be used for secondary, non-load-bearing components of containers. Welded connec-tions between these steels and those specified in 2.1.1shall not negatively affect the structural components.

2.2 Cast steel

2.2.1 Cast steel grades GS-38, GS-45 and GS-52 toDIN 1681 as well as GS-C 25 to DIN 17245 and cast

steel grades conforming to DIN 17182 may be used forcastings for the components specified in 1.1. Cast steelfor corner fittings shall meet the requirements of para-graph 2.3.3. Cast steel grades satisfying other rules orstandards may also be used with the Societys consent,provided that they are equivalent to the foregoinggrades in respect of mechanical characteristics andweldability.

2.2.2 Unless otherwise agreed on, steel castings(except those for corner fittings) are subject to thequality requirements and test conditions contained inChapter 2 of the Rules for Materials of GermanischerLloyd in association with the standards.

2.2.3 Steel castings for corner fittings shall con-form to the following requirements:

The composition of each charge shall conform toTable 1 and shall be certified by the manufac-turer.

Deviations from the chemical composition re-quire the Society's consent.

The mechanical properties shall meet the re-quirements of Table 2.

Deviations require the Society's consent.

2.2.4 The steel castings shall be supplied in eithernormalized or heat-treated condition, depending on thecast steel grade.

2.2.5 Steel castings shall not exhibit any defects(such as shrinkholes, blowholes or cracks) which mayadversely affect their use and adequate working. Un-important sand marks and slag spots, small cold shutsand minor scabs shall be gouged out if necessary.

2.2.6 Elimination of defects (including so-called

blemishes) by welding is permissible only with theSociety's consent 2.

In observance of the Society's Rules for Materials,Chapter 2, Section 4.A. ., the welding process, heattreatment process and scope of testing shall be agreedwith the Society prior to the commencement of suchwelding work.

2 Preconditions for the granting of the welding permission are:

employment of trained welders supervised during work, use of suitable, approved welding filler metals, workmanlike removal

and crack detection testing of the defect area, preheating forwelding to approx. 100 C if necessary, subsequent stress-relief annealing; in the case of major defects, renewed normalizing,machining of the welded areas and crack detection testing bymeans of non-destructive testing methods.
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Table 1.1 Chemical composition (melt analysis) 1

Composition (%)

Cmax

Mn Simax

Pmax

Smax

Crmax

Nimax

Cumax

Momax

Alsol 2

minCr+Ni+Cu+Mo

max

0,200,90

to1,50

0,50 0,035 0,035 0,25 0,30 0,20 0,08 0,015 0,70

1 The carbon equivalent shall not exceed 0,45 %.C CMn Cr Mo V Ni Cu

eq = + + +

++

( )6 5 15

%

2 Aluminium may be partly or completely replaced by other fine-grain-forming elements.

Table 1.2 Mechanical properties

Yield point

R eH[N/mm 2]

min

Tensile strength

R m[N/mm 2]

Elongation

A5[%]min

Reduction incross-section

Z[%]min

Impact energy

KV 1

[Joule]min

bei 20 C 2

220430to

60025 40 27

1 Average value from three specimens:One individual value may be lower than, but not less than 70 % of the average value.

2 If lower testing temperatures are demanded by the purchaser in special cases, these are to be agreed with the Society.

2.2.7 With all cast steel grades, testing shall consistof tensile and notched bar impact tests.

For sampling, pieces shall be grouped into test lotsaccording to melting and heat treatment batches.

The test specimens shall in general be cast integrallywith the casting and may be cut off only after finalheat treatment and stamping.

Where integral casting is not possible, test specimensshall be taken from odd pieces or separately cast testspecimen coupons, by agreement with the Surveyor.

2.2.8 Where the material is tested by the Society,all castings shall be presented to the Surveyor forchecking in respect of their as-cast condition and theirdimensions. Dimensional and visual checks are usuallycarried out at random. At the request of the Surveyor,non-destructive tests, e.g. by means of magnetic parti-cle or dye penetrant methods, shall be carried outshould serious defects be suspected.

In the case of container corner fittings, one out of every 400 castings originating from the same chargeshall be tested for internal defects by an appropriatemethod.

2.2.9 Each casting shall be marked with the manu-facturers symbol and the charge number (at least thelast three digits). Agreements between purchaser andfoundry shall be reached as regards additional mark-ings such as drawing or item numbers.

Where the material testing is carried out by the Soci-ety, each casting tested by the Surveyor shall be

marked with the G L test stamp; all other castingsforming part of the delivery in question shall be

marked with the stamp for batch testing . 3

3 In place of the stamp, another type of marking such as the

cast-in letters "GL" may be used for identifying GL-testedcastings provided that the Society has consented hereto.


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Test specimens and castings from which test speci-mens have been taken shall be marked with the test

specimen stamp .

2.3 Stainless steels

2.3.1 Stainless steels shall be selected with respectto their resistance to corrosion considering the cargo tobe transported and the conditions of working (weld-ing). Unless otherwise agreed upon in detail, steelsconforming to DIN 17440 or, with the Societys con-sent, equivalent steels conforming to other rules orstandards may be considered.

2.3.2 Only grades suitable for welding applicationsand with guaranteed resistance to intercrystalline cor-

rosion in the welded condition (without heat treatment)may be used for weldments. These are in general thetitanium- or tantalum/niobium-stabilized grades orthose with a reduced carbon content (approx. 0.02% -0.05% C).

3. Aluminium alloys

3.1 Wrought alloys

3.1.1 Wrought aluminium alloys must show suffi-

cient resistance to corrosion in a seawater-laden at-mosphere. Unless otherwise agreed upon in a particu-lar case, the alloys Al Mg 3, Al Mg 4.5 Mn, Al Mg Si0.5, Al Mg Si 0.7 or Al Mg Si 1 to DIN 1725 Part 1shall be used.

3.1.2 The chemical composition and mechanicalproperties shall conform to the Societys Rules forMaterials and the relevant standards.

In respect of weldments, only the strength in the softcondition may be taken into account.

The Society may agree to the use of a higher strengthvalue if corresponding evidence is furnished, e.g. in anapproval test.

3.2 Cast alloys

3.2.1 3.1.1 applies as appropriate to the corrosionresistance of cast aluminium alloys. The following castalloys to DIN 1725 Part 2 may be used; see Table 1.3.

3.2.2 Cast aluminium alloys shall have quality

properties sufficient for the relevant application. Cor-ner fittings made from cast aluminium alloys are sub-

ject to the Societys special approval, evidence of suf-ficient strength properties having to be furnished.

Table 1.3 Cast aluminium alloys suitable for sea-water duty

Material designationaccording to

DIN 1725, Part 2

Suitability for seawaterduty according toDIN 1725, Part 2

G/GKAl Si 12G/GKAl Si 10 Mg waG/GKAl Si 9 Mg waG/GKAl Si 7 Mg waG/GKAl Si 5 Mg ka/waG/GKAl Mg 3G/GKAl Mg 3 SiG/GKAl Mg 5G/GKAl Mg 5 SiGdAl Mg 9

goodgoodgoodgoodgood

excellentvery goodexcellentvery goodvery good

4. Wooden materials

4.1 Manufacturers of wooden components forcontainers (solid wood, laminwood or plywood) shallhave an independent works control department. Alaboratory equipped with suitable, calibrated testinginstruments must be available.

4.2 Only service-proven species of timber, that is,timber featuring good resistance to water, atmosphericconditions, fungi and insect infestations as well asgood mechanical properties appropriate to the applica-tion and a low swelling and shrinking tendency shallbe used for any wooden components used in the manu-facture of containers.

4.3 Solid wood

Grown wood used in container construction must belong-fibred and of good quality, that is, free from sap,deleterious knots and other defects. Twisted graintimber or wood cut across the grain shall not be used.

The timber used must either be well seasoned andsufficiently dry or be expertly dried in suitable dryingkilns.

4.4 Plywood, laminwood

Plywood and other wooden elements made up of partsglued together shall consist, in all their layers, plies orparts, of timber of a strength sufficient for the applica-tion concerned. The quality requirements for plywoodboards shall be laid down in accordance with DIN68705, page 2, or other equivalent standards. Whenmanufacturing plywood boards etc., proven types of glue shall be used. The glued joints shall conform toDIN 68705 AW 100 as well as to DIN 53251 and DIN53255.


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4.5 Wood protection

All wood should be protected against infestation byfungi and/or insects by impregnating it with a service-proven wood preservative (cf. B.4..).

The underside of wooden floor parts should, if possi-ble, be sealed by suitable means (e.g. phenolic resin)to protect them against moisture.

5. Plastic materials

5.1 Glass-fibre-reinforced plastics used as liningsor coatings of wall and roof elements shall be of serv-ice-proven quality and applied in accordance withproven methods. The strength of the coating and of thecore layers (wood, plastic, etc.) shall be adapted to oneanother in accordance with the requirements in Section

2, B.2 . The Society reserves the right to require specialproof.

5.2 Plastic materials used as coatings, linings orinsulation in containers shall withstand the climaticand mechanical stresses occurring and shall not giveoff any substances detrimental to health or the cargo(see also Section 3, A.3 ).

5.3 For requirements in respect of sealing ele-ments, see C.3.2.5 .

E. Jointing methods

1. Welding

1.1 Conditions applying to works and shops

1.1.1 Works and shops wishing to carry out weld-ing work on containers shall be approved by the Soci-ety in this respect (see also Section 1, A.4. ). The TCApproval Regulations shall be complied with in re-spect of tank containers for the transportation of dan-

gerous goods. The works and shops shall possess ap-propriate facilities permitting expert welding work of high-quality workmanship. These facilities shall in-clude working places protected against atmosphericinfluences, machinery and equipment for expert prepa-ration of the joints to be welded, safe and reliablewelding machinery and equipment, and stationary orportable drying spaces or cabinets for storing thewelding filler metals and consumables.

1.1.2 For assembly and welding, it is advisable touse jigs in order to ensure dimensional stability of thestructural components. These jigs shall be of such aconfiguration that the weld seams are easily accessibleand can be welded in the most favourable positionpossible (cf. also i.a. 1.6.5 ). Tack welds shall beavoided wherever possible.

1.2 Welders, welding supervisors

1.2.1 All welding work on structural parts in accor-dance with Section 1, D.1.1 may only be carried outonly by adequately qualified welders approved by theSociety who hold valid welders qualification certifi-cates. The welders shall have been qualified in accor-dance with DIN EN 287 or (with the Societys consent)other equivalent standards in one or more qualificationgroups in such a way that the field of work in question(materials, thicknesses of structural components,welding process and positions, welding filler metals,etc.) is covered thereby. The supplementary provisionsin the Societys Rules for Welding with regard to in-clusions and exclusions shall be observed (e.g. therequirement for additional fillet weld test pieces if fillet welds are to be made as well). Welders who are

to weld vertical downward seams shall have beenqualified in this position as well (see 1.3.1 and 1.6.5 ).

1.2.2 The validity of a welders certificate (nor-mally two years), the conditions for maintaining thevalidity of certificates and the re-examinations aregoverned by the particulars of DIN EN 287 and theSocietys Rules for Welding.

1.2.3 Every works or shop carrying out weldingwork shall have in its employ a welding supervisor,proof of whose professional qualifications shall befurnished to the Society. Depending on the type andscope of the welding work to be carried out, the weld-ing supervision may be performed by, e.g., a weldingspecialist or a welding engineer. The welding supervi-sion is to be approved by the Society. Changes in re-spect of the welding supervisors shall be communi-cated to the Society without delay. The welding super-visor shall responsibly supervise the preparation andexecution of the welding work (see also 1.6.8 ).

1.3 Welding processes, procedure testing

1.3.1 Only welding processes, the suitability of

which for the application concerned is accepted on thebasis of general experience or has been proved in aprocedure test shall be used. Procedure tests super-vised by the Society shall in any case be conducted oncorner fittings for vertical downward welding andsingle-side welding of hollow metal sections to furnishproof of satisfactory shop procedures and adequatequalitative properties under production conditions inthe users works. Moreover, the Society is also entitledto call for procedure testing for other welding proc-esses or materials (e.g. special structural steels).

1.3.2 The scope of testing, samples, test specimens

and requirements are laid down on a case-by-casebasis by analogy with the Societys Rules for Weldingin accordance with the range of application appliedfor. Welders employed in procedure tests are consid-
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ered qualified in the welding technique concernedand/or in connection with the respective materials,provided that the procedure tests have been success-fully completed. Where further welders or operatorgroups are to be employed in the case of a subse-quently enlarged range of application, the welders andoperator groups are to be adequately trained and tested(see 1.2.1).

1.4 Welding filler metals and consumables

1.4.1 All welding filler metals and consumablesused (such as rod electrodes, gas-shielded weldingwires, etc.) shall have been approved by the Society inaccordance with the Societys Rules for Welding. Therequired quality grade depends on the base materials tobe welded.

1.4.2 Filler metals and consumables of any qualitygrade may be used for ordinary-strength hull structuralsteels and equivalent structural steels such as steelgrades Fe 360 or Fe 430 to DIN EN 10025 (cf. Section1, D.2.1.1 ). Grade 2 Y and 3 Y filler metals and con-sumables (where necessary, those with the extension H15, H 10 or H 5) shall be used for higher-strength hullstructural steels and equivalent structural steels such asFe 510 to DIN EN 10025. The filler metals and con-sumables last mentioned shall be preferred for weldingrimming structural steels and cast steels.

1.4.3 Particulars of the range of application of theapprovals of welding filler metals and consumables forother materials (such as austenitic stainless steels oraluminium alloys) are contained in the Societys Rulesfor Welding.

1.4.4 Welding filler metals and consumables forother materials may also be tested and approved inconjunction with the procedure in question. However,such approvals remain restricted to the users worksand have a maximum validity period of one year un-less repeat tests are carried out. Filler metals and con-sumables included in the procedure test in this waymay be replaced with other equivalent filler metals andconsumables of corresponding quality, approved assuch by the Society.

1.5 Configuration of welded joints

1.5.1 The welded joints shall be designed from theoutset in such a way that they are easily accessibleduring manufacture and can be made in the most fa-vourable welding sequence and welding position pos-sible. Care shall be taken that only the inevitableminimum of residual welding stresses and distortions

will remain in the structural components after manu-facture. Small distances of the welded joints from oneanother and local accumulations of welds shall beavoided.

1.5.2 Welding in cold-formed areas with more than5 % permanent elongation is to be avoided as far aspossible in the case of structural steels susceptible tostrain ageing. Welding work may be carried out incold-formed and adjacent areas of hull structural steelsand equivalent structural steels (e.g. of quality groupsB, D, D 1, D 2, DD 1 and DD2 to DIN EN 10025)provided that the following minimum bending radii(inside) are adhered to (Table 1.4).

Table 1.4

Sheet / plate thickness range

Minimum bendingradius (internal)

up to 4 mmover 4 to 8 mm

over 8 to 12 mm

1 sheet thickness1,5 sheet/plate

thickness2,0 plate thickness

Depending on the bending process, a larger bendingradius than that indicated above may be necessary.

1.5.3 Butt-welded joints (such as straight buttwelds, V- or double-V welds) and corner or cross

joints (such as single-bevel butt welds) shall normallybe designed in such a way that the full plate or shapecross section is fused. To achieve this, the structuralcomponents shall be prepared with appropriate weldshapes to DIN standards (e.g. DIN 8551, DIN 8552etc.), being given a sufficient included angle betweenthe planes of the fusion faces, a sufficient air gap, andthe smallest possible depth of the root faces, depend-ing on the sheet or plate thickness. Special weld shapesrequire the Societys approval; where necessary, theweld shapes are laid down in connection with a proce-dure test.

1.5.4 Fillet welds shall, wherever possible, be sodesigned as to be continuous on both sides (cf.C.3.2.1 ). Welds intermittent on the inside may bechosen for welding walls etc. to the inside of theframework. Only fillet welds continuous on both sidesor intermittent fillet welds with scallops in the websmay be provided for tanks, with the fillet welds takenaround the stiffener or scallop ends to seal them. Thefillet throat depends on the load in each case, andcalculated proof of its adequacy shall be furnished incases of doubt. The "a" dimension shall not exceed 0.7t (t = thickness of the thinner part). With the exceptionof fillet welds on walls and similar structural compo-nents made of sheet metal, the fillet weld throat "a"shall be not less than 2.5 mm and, on corner fittings,not less than 3.5 mm.


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1.5.5 Overlapped welded joints shall be used onlyin connection with structural components subject torelatively small loads and shall, wherever possible, beused only parallel to the direction of the main stress.The overlap width shall be at least 1.5 t + 15 mm, tbeing the thickness of the thinner plate. The filletwelds shall be executed in accordance with 1.5.4.

1.6 Manufacture and testing

1.6.1 The structural components shall be clean anddry in the area of the weld. Any scale, rust, flame-cutting slag, grease, paint (with the exception of per-mitted production coatings with a film thickness of upto 20 approx.) and dirt shall be thoroughly removedprior to welding. Where plates, shapes or structuralcomponents are provided with a corrosion-reducingproduction coating (shop primer) prior to welding, thiscoating shall not affect the quality of the welded joints.

1.6.2 When preparing and fitting together thestructural components, care shall be taken to complywith the specified weld shapes and gap widths (airgaps). If the permissible gap width is slightly ex-ceeded, it may be reduced by deposit welding on thefusion faces of the joint. Filling pieces or wires shallnot be welded in. Larger gaps may be closed by weld-ing in a sufficiently large metal strip or shaped section.

1.6.3 Plates and sections shall be accuratelyaligned, in particular in structures interrupted bycrossing members. A displacement of the edges rela-tive to one another of more than 15 % of the plate orsection thickness or more than 3 mm, whichever is thesmaller, is not acceptable.

1.6.4 During welding operations, the areas wherework is carried out shall be protected against atmos-pheric influences. In cold air (below 0 C) suitablemeasures shall be taken (covering, heating the cornerfittings) to ensure satisfactory execution of the welded

joints. Welding shall cease at temperatures below- 10 C. Any rapid cooling down shall be avoided,especially when welding corner fittings.

1.6.5 Welding work shall be carried out in the mostfavourable welding position possible. Welding in avertical downward position shall be avoided whereverpossible on corner fittings and is not to be carried outat the corner fitting/corner post connection, even aftera procedure test for vertical downward welding ingeneral and irrespective of the approval of the weldingmetals and consumables. The use of a suitable weldingsequence shall ensure the least possible restriction of the shrinkage of the weld seams.

1.6.6 In welding operations, care shall be taken toachieve uniform penetration, perfect fusion down to

the root, and uniform, not excessively convex weldsurfaces. In the case of multi-pass welding, slag origi-nating from the preceding runs shall be thoroughlyremoved. Cracks (including broken tack welds), largerpores or slag inclusions etc. are not to be welded overbut shall be gouged out.

1.6.7 The repair of major material or workmanshipdefects may be carried out only after the Society hasgiven its consent. Minor surface defects shall, wher-ever possible, be eliminated only by shallow grinding.Defects which reach deeper into the weld shall becleanly gouged out and rewelded.

Where in the case of cracks total or partial replace-ment of the structural component concerned is notdemanded or the cracks may be closed by weldingwith the Societys consent, the length and configura-tion of the crack shall be unambiguously ascertainedby means of a suitable crack detection technique, thecrack cut out to beyond its ends and subsequentlywelded up.

1.6.8 Workmanlike accomplishment of the weldingshall be ensured by careful control carried out by theshop concerned (see 1.2.2 ). The Society will check thewelding work at random during fabrication and, wherenecessary, during the final inspection after completion.The Society is entitled to reject insufficiently checked

structural components and to require them to be sub-mitted anew following a successful in-shop check andon completion of any repairs necessary.

1.6.9 In cases of doubt, the Society is entitled todemand that additional tests (such as non-destructivetests to furnish evidence of the satisfactory weld qual-ity) be carried out on important structural components.The type and scope of the tests will be laid down bythe Society from case to case. For testing of tank con-tainers, see Section 6 .

2. Bolted and riveted connections

2.1 It is assumed that jointing elements con-forming to the relevant standards and laid down in thepurchasers specification will be used and the connec-tions made in accordance with current engineeringpractice.

2.2 The adequate strength of a connection is ingeneral considered proven if the tests in Section 2 havebeen conducted without giving cause for complaint.The Society is entitled to call for a procedure test inspecial cases. Where necessary, calculations serving asevidence shall be submitted together with the docu-ments subject to examination.
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2.3 All the elements of the connection shall beresistant to seawater. Subsequent application of a coatof anti-corrosive paint is not considered sufficient. Thepossibility of contact corrosion is especially to bereckoned with. In the case of tank and bulk containers,the jointing elements shall moreover be resistant to thesubstances intended to be carried in these containers.

2.4 Connections between steel and aluminiumstructural components shall be made in such a way asto be corrosion-inhibiting in a service-proven manner.

2.5 Bolted connections shall be locked in certaincases. This may in particular apply to the mounting of refrigerating machinery sets or parts thereof as well asto safety valves and fittings.

2.6 With regard to the locking of bolted connec-tions for customs purposes, the official regulationsshall apply.

2.7 Proof shall be furnished that the rivet materialis not embrittled by clinching the rivets.

3. Adhesive joints

3.1 The suitability (durability) of adhesive joints(e.g. for fixing of wall panels) shall be proved in aprocedure test. The type and scope of this test shall be

agreed in each individual case. Previous experiencemay be taken into account.

3.2 In respect of joint preparation and handlingconditions, the instructions given by the adhesivemanufacturer shall be complied with.

3.3 The components of the adhesive joints shallbe insensitive to the climatic and chemical actions tobe expected and harmless with respect to the cargo tobe transported.

F. Marking and documentation

1. Marking

1.1 Containers which have been tested in accor-dance with B.3.1 are marked with:

a) An adhesive label in conformity with Annex B,B.., normally on the left door

(Tank containers: beside the tank rating plate)

b) The number of the type certificate (FC No.), theGL stamp, and the tank test number are addi-tionally die-stamped into the rating plate of thetank of tank containers.

1.2 GL stamps and labels refer to the as-manufactured (as-delivered) condition of the con-tainer. Their renewal after repair or loss is permittedonly in consultation with the Societys Head Office orcompetent Inspection Office. Labels are issued only bythe Society.

1.3 CSC plate: The Safety Approval Plate re-quired by the Law covering the Convention for SafeContainers (CSC) of December 2nd, 1972 shall bedurably fixed, be resistant to fire and corrosion, andcontain the particulars shown in Annex B, B.2.. TheApproval Reference will be laid down by the compe-tent approving authority.

1.4 Markings relating to checking by the customs

authorities shall be affixed in accordance with theprovisions issued by the competent authority.

1.5 In respect of the transportation of dangerousgoods, the marking is to be made in accordance withthe legal provisions (e.g. IMO Code).

1.6 Markings in connection with approval forrailway traffic (e.g. in accordance with UIC condi-tions) shall be made in accordance with the provisionsissued by the railway administrations.

1.7 Where wooden structural components havebeen impregnated and tested on the basis of specialrules or regulations, the containers may be markedwith a permanently affixed label corresponding to thenational provisions in question.

1.8 In all other respects, for marking of contain-ers the international standard ISO 6346 "Freight Con-tainers Coding, identification and marking" is to becomplied with.

2. Documentation

2.1 Type certificate

2.1.1 The testing of the container type, that is, thescrutiny of the documentation (drawings etc.) and theload and operating tests, is certified in the type certifi-cate (see Annex B, C.1.). This certificate also containsthe most important particulars of type and design,manufacturer and purchaser.

2.1.2 In the case of small series, the results ob-tained while testing a preceding series may be referredto as regards the type certificate, by agreement withthe Society's Head Office.


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2.2 Individual certificates

2.2.1 The testing of the individual containers of aseries (supervision of production and individual testing

in accordance with B.3.1 ) is confirmed by an individ-ual certificate (see Annex B, C.2. or C.3, as applica-ble).

2.2.2 The individual certificates covering contain-ers subjected to regular checks in accordance with

B.6.1.3 may be renewed or their validity may be ex-tended.

2.2.3 Special tests and repair or damage surveys of containers may be informally certified by the SocietysHead Office or the Inspection Office that has carriedout the tests or surveys.


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B

Section 2

Requirements and Tests

A. General Requirements

1. Load assumptions

1.1 The loads relevant for the individual struc-tural components follow from the test conditions con-tained in B., unless different details are furnished bythe purchaser. When choosing the safety margins inrespect of the possible failures, material fatigue, nor-mal manufacturing inaccuracies, and possible differ-ences in quality of the materials (wood!) shall be takeninto account.

1.2 Where the Society is requested to certifyconformity with the law covering the convention forsafe containers (CSC) and with the ISO standards, atleast the test loads according to B. shall be applied inthe type test.

1.3 Where roofs are to be capable of supporting

not only persons but also cargo (e.g. thermal contain-ers for suspended cargo), the load indicated by thepurchaser shall be taken into account when designingand testing the container (cf. Section 3, B.5.2.2 ).

2. Deformations

2.1 On completion of the load tests in accordancewith B.2.1 to 2.14 , the container shall not exhibit anypermanent deformation which affects its usefulnessand traffic safety (loading capability, tightness). Ref-erence values for some permitted permanent deforma-

tions are indicated in B, Table 2.3 .

2.2 Elastic deformations under load depend onthe construction; their admissibility is governed by theindividual transportation conditions. The return of thebase structure as per Section 1, C.3.2.1.2 shall be sochosen within the range indicated therein that thelower face of the base structure does not deflect morethan 6 mm below the lower bearing planes of the cor-ner fittings with the container loaded to 1.8 R.

2.3 The end structure shall be sufficiently rigid to

ensure that a transverse force of 150 kN applied to thehighest point of this plane does not cause the sum of the changes in length of the diagonals to exceed60 mm.

2.4 The side structure shall be sufficiently rigid toensure that a 75 kN shear force applied to the highestpoint of this plane does not cause the point of applica-tion of this force to shift longitudinally by more than25 mm.

2.5 Platform containers with fixed or foldable endwalls shall be sufficiently rigid to ensure that a shearforce of 50 kN applied at the top corner fitting does

not cause a longitudinal deflection of more than 42mm.

B. Tests

1. General guidance

1.1 The tests indicated below are the minimumrequirements in respect of ISO general cargo contain-ers and, where applicable, in respect of all specialtypes of ISO Series I freight containers (see Annex A,Table A.1). They should also form the basis for testingcontainers not conforming to the standards.

1.2 The strength tests according to these Regula-tions shall be carried out exclusively as static tests inorder to obtain comparable and reproducible test data.Allowances have been made in the test loads for dy-namic load components. Accordingly, care shall betaken to apply the test loads slowly (without noticeabledelay or acceleration) and to keep them effective for atleast 5 minutes.

1.3 During the tests, deformation measurementsshall be carried out at certain points of the containerunder test. Care shall be taken to carry out zero meas-urements prior to, and after, the application of loads orforces.

We recommend that the GL type testing report, inwhich the aforementioned measuring points are indi-cated, be used for recording the test results.

1.4 Repeat tests (cf. Section 1, B.3.3 ):

Table A.3 in Annex A furnishes a basis for the fre-quency of repetition of individual tests during fabrica-tion. The exact test programme shall be laid down ineach individual case.


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1.5 The routine testing (identity of materials,workmanship, dimensional stability, operational test-ing of closures and locks, tightness) is carried out atrandom at the Surveyors discretion during fabrication.

1.6 The tests detailed in B.2 . may be carried outin any sequence within a complete type test, with thefollowing exceptions:

Test no. 1 (stacking) shall be carried out before testsnos. 2 and 3 (lifting from the top and bottom cornerfittings). Test no. 13 (weatherproofness) shall be car-ried out last.

1.7 With the door-fitted wall under transverseloading, tightness of the door seal to spray shall beproved under half the test load (cf. Section 2, B.2.9and B.2.13 ).

1.8 The test loads shall be applied in such a waythat the rigidity of the structural component under loadis not changed and the effect intended (uniformlydistributed or point load) is achieved.

2. Description of the tests

2.1 Test No. 1 Stacking

This test is intended to show whether a fully loadedcontainer can support the total weight stacked on top

of it as per the table below. The accelerations of thevessel and the relative misalignment of containers dueto clearances in the guide rails shall be taken into ac-count.

The container under test shall be placed on four levelpads, one under each bottom corner fitting or equiva-lent corner structure. The pads shall be positionedcentrally under the corner fittings and have approxi-mately the same base area as the corner fittings. Thecontainer shall have a load uniformly distributed overits floor in such a way that the total weight of the con-tainer equals 1.8 R.

The container shall be loaded with vertical loads whichare applied either to all four corner fittings simultane-ously or at each pair of one end. The loads are to betaken from the table below.

Guidance:

The test load of 3 392 kN per container is derived from9-high stacking, i.e. 8 containers each weighing 24000 kg at an acceleration of 1.8 g are stacked on top of a container. (The corner posts of such containers aretested with a test load of 848 kN).

Care shall be taken to ensure that the plane of applica-tion of forces and the plane of the supports under thecontainer remain horizontal and unchanged during

testing. The force shall be applied through an interme-diate pad with the same base area as a corner fitting.Each intermediate pad shall be offset by 25.4 mmlaterally and 38 mm longitudinally.

When testing platform containers with foldable endwalls, the stacking test shall also be performed withthe end walls folded.

2.2 Test No. 2 Lifting from the top cornerfittings

This test is intended to prove that containers can belifted by their top corner fittings using a verticallyapplied load-carrying means.

Containers of sizes 1 D, 1 DX, 1 E and 1 F shall beraised using standard lifting gear in such a way that theangle of the lifting wires is 30 to the vertical.

This test is also intended to show whether the loadingcapability of the floor is adequate to withstand theacceleration forces encountered in loaded containers

when handled by cranes.

Table 2.1

Type of containerTotal test load (applied to all 4corner posts simultaneously)

[kN]

Test load oneach end frame

[kN]

Allowablestacking weight

[kg]

1 A, 1 AA + 1 AAA + 1 AX1 B, 1 BB + 1 BBB + 1 BX1 C, 1 CC + 1 CX1 D + 1 DX

3.3923.3923.392

896

169616961696

448

192.000192.000192.000

50800


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The container under test shall have a load uniformlydistributed over the floor in such a way that the com-bined weight of the container and test load equals 2 R.The container shall be lifted at the four top corners insuch a way that no substantial acceleration or decel-eration forces occur.

Platform containers with fixed and foldable end wallsshall keep the following dimensions (measured overthe top corner fittings) at a loading of 1 R:

Table 2.2

Type of container L max.empty

L min.loadedto 1 R

1 AAA, 1 AA, 1 A und 1 AX

1 BBB, 1 BB, 1 B und 1 BX

1 CC, 1 C und 1 CX

12.202

9.135

6.068

12.172

9.105

6.042

L = longitudinal distance between outer edges of corner fittings

2.3 Test No. 3 Lifting from the bottomcorner fittings

This test is intended to prove that the container can belifted by means of lifting devices bearing on the bot-tom corner fittings only and attached to a single trans-verse central spreader beam above the container.

This test shall be carried out on containers of all sizes.

It shall also be carried out on 1 E and 1 F containers if they are equipped with bottom corner fittings.

The container under test shall have a load uniformlydistributed over its floor in such a way that the com-bined weight of the container and the test load equals 2R.

The container shall be carefully lifted by its four bot-tom corner fittings in such a way that no noticeable

acceleration or deceleration forces occur. The liftingforces shall be applied at an angle of:

30 to the horizontal for 1 AAA, 1 AA, 1 Aand 1 AX containers

37 to the horizontal for 1 BBB, 1BB, 1 B and1 BX containers

45 to the horizontal for 1CC, 1 C and 1 CXcontainers

60 to the horizontal for 1 D and 1 DX con-

tainers.The lines of action of the lifting forces and the outerfaces of the corner fittings are to be no farther apartthan 38 mm.

During lifting, the lifting equipment shall bear on thebottom corner fittings only. The lifting equipment shallbe similar to the lifting devices customary in handlingpractice.

2.4 Test No. 4 Restraint test (longitudinal)

This test is intended to prove the ability of the con-tainer to withstand longitudinal external restraintcaused by dynamic acceleration loads of up to 2 gduring movement by rail.

Containers of all sizes and also 1 E and 1 F containerswith bottom corner fittings shall be subjected to lon-gitudinal forces. 1 E and 1 F containers shall addition-ally be subjected to transverse forces.

The container shall have a load uniformly distributed

over the floor in such a way that the combined weightof the container and the test load equals 1 R.

The container is to be anchored at one end through thebottom apertures of the bottom corner fittings. A forceacting horizontally and equivalent to 2 R in total shallbe applied to the container through the bottom aper-tures of the other corner fittings, first towards and thenaway from the anchor points.

2.5 Test No. 5 Loading the end wall

This test is intended to prove the ability of the con-tainer to withstand longitudinal external forces whichare imposed by dynamic loads up to 2 g during move-ment by rail.

Each end of a container is to be tested when one end isblind and the other is equipped with a door. In the caseof symmetrical construction, one end only need betested. Containers shall be subjected to an internal loadof 0.4 P. Bulk containers and 1 E and 1 F containersshall be subjected to an internal load of 0.6 P. Theinternal load shall be uniformly distributed over thewall under test. The arrangement shall allow free de-flection of the wall.

2.6 Test no. 6 Loading the side walls

This test is intended to prove the ability of the con-tainer to withstand the forces resulting from shipmovements.

Each side wall (or only one in the case of symmetricalconstruction) shall be separately subjected to a uni-formly distributed internal load of 0.6 P. The loadshall be applied in such a way as to allow free deflec-tion of the side wall and the top and bottom side rails.

Open top containers shall be tested in the state inwhich they are used in service, e.g. with removableroof bows in position. Special arrangements may bemade for 40-foot containers.


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2.7 Test No. 7 Loading the roof

This test is intended to show whether a rigid roof

a) is capable of withstanding the loads imposed bypersons working on it, or

b) if intended to carry hanging loads, has a loadingcapability corresponding to the load, but at least1 490 kg per metre of usable internal containerlength, if a vertical acceleration of 2 g is takeninto account.

The tests shall be carried out as follows:

a) A load of 300 kg shall be uniformly distributedover an area of 600 mm by 300 mm located atthe weakest point of the container roof.

b) The roof shall be loaded with twice the weight

of the intended hanging cargo, but with at least2 1490 kg/m, with the container resting onlyon its four bottom corner fittings.

2.8 Test No. 8 Loading the floor

This test is intended to prove the ability of the con-tainer floor to withstand the concentrated dynamicloads imposed by fork lift trucks or similar devicesduring loading and unloading operations.

The test is carried out on containers of all sizes.

The test shall be performed using a rubber-tyred testvehicle loaded to an axle weight of 5 460 kg, that is, 2730 kg per wheel. The nominal wheel width shall be180 mm and the centres of the two wheels shall be 760mm apart. The contact area of any one wheel shall becircumscribed by a rectangle measuring 185 mm by100 mm. Each wheel shall have an actual contact areaof not more than 142 cm 2 lying within the above men-tioned rectangle.

2.9 Test No. 9 End wall rigidity (trans-verse rigidity)

This test is intended to prove the ability of containersto withstand the transverse racking forces in the endframes resulting from ship movements.

The container under test is to be placed in unladen(tare) condition on four level pads, one under eachbottom corner fitting, and to be anchored through thebottom apertures in such a way that no vertical move-ment is possible. Lateral restraint of an end wall is tobe provided only at the bottom corner fitting diago-nally opposite to, and in the same end frame as, the topcorner fitting to which force is applied. Where the two

end frames are tested separately, vertical anchoringshall be provided only at the end frame under test.

Forces of 150 kN shall be applied either separately orsimultaneously to each of the top corner fittings on one

side of the container parallel to both the end wall andthe base plane. The forces shall be applied first to-wards and then away from the top corner fittings.Where the end walls of the containers are identical,only one end wall need be tested. Where an end wall isessentially asymmetrical about its own vertical centreline, the end wall shall be tested from both sides.

2.10 Test No. 10 Side wall rigidity (longitu-dinal rigidity)

This test is intended to prove the ability of containersto withstand the longitudinal racking forces in the sideframes resulting from ship movements.

The container under test is to be placed in unladen(tare) condition on four level pads, one under eachbottom corner fitting, and to be anchored through thebottom apertures in such a way that no vertical move-ment is possible. Longitudinal restraint of a side wallis to be provided only at the bottom corner fittingopposite to, and in the same side frame as, the topcorner fitting to which force is applied.

Forces of 75 kN shall be applied either separately orsimultaneously to each of the top corner fittings at oneend of the container parallel to both the side wall andthe base plane. The forces shall be applied first to-wards and then away from the top corner fittings.

Platform containers with fixed or foldable end wallsshall be loaded with a force of 50 kN on one or bothtop corner fittings of an end wall, parallel to the sideand base planes. The forces shall be applied first to-wards and then away from the bottom corner fittings.The deflection of the end wall shall not exceed 42 mm.

In the case of a container with two identical side walls,only one side wall need be tested.

2.11 Test No. 11 Lifting by means of a forklift truck

This test is intended to prove the ability of 1 CC, 1 C,1 CX, 1 D, 1 E and 1 F containers to withstand theloads encountered when being lifted and transportedby fork lift trucks.

a) 1 CC, 1 C and 1 CX containers equipped withonly one set of fork lift pockets and 1 D, 1 DX, 1E and 1 F containers:

The container shall have a load uniformly dis-tributed over its floor in such a way that thecombined weight of the container and the testload equals 1.6 R. The container shall be sup-ported on two horizontal bars, each 200 mmwide and projecting 1 828 mm 3 mm into thefork lift pockets, measured from the outside faceof the container side wall. The bars shall becentred within the pockets.


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b) 1 CC, 1 C and 1 CX containers equipped withtwo sets of fork lift pockets:

The procedure in a) applies to the outer fork lift

pockets, while the inner ones are subject to thefollowing procedure:

The container shall have a load uniformly dis-tributed over its floor in such a way that thecombined weight of the container and the testload equals 0.625 R. The container shall be sup-ported on two horizontal bars as in a), insertedinto the additional inner fork lift pockets.

2.12 Test No. 12 Lifting by means of grap-

pler arms

This test is intended to prove the ability of suitablyequipped containers to withstand the loads encoun-tered when being handled by means of grappler arms.

The container under test shall have a load uniformlydistributed over its floor in such a way that the com-bined weight of the container and the test load equals1.25 R. The container shall be supported at the fourpositions where provision has been made for the grap-pler arms. Each of the support surfaces shall measure

32 mm by 254 mm and be located clear of the safetylip.

2.13 Test No. 13 Weatherproofness

This test is intended to prove the ability of the con-tainer to protect its cargo adequately against externalmoisture.

All the exterior joints and seams shall be tested bymeans of a jet of water from a nozzle of 12.5 mminside diameter, at a pressure of approx. 1 bar corre-sponding to a head of water of 10 m. The nozzle shallbe held at a distance of 1.5 m from the container undertest. The jet shall be traversed at a rate of 100 mm/sec.

Procedures involving the use of several nozzles areacceptable only on condition that each joint or seam iscovered in the same way as when using a single noz-zle.

Concerning the combination of this test with test no. 9,

see Section 2, B.1.7 .

2.14 Test No. 14 Tensile loading of the lash-ing lugs

This test is intended to prove the ability of the lashingpoints of a correspondingly equipped container towithstand the dynamic loading forces resulting fromship movement.

A test load equal to 1.5 times the specified lashingforce shall be applied to the lashing point to be tested.Wherever possible, the test load shall be applied at an

angle of about 45 to the horizontal and maintained forat least 5 minutes.


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Table 2.3 Principles for container testing

Scope of type test Measuring

Test procedure Permissible values

No. and/or

designrequirements

pointInternal

loadMethod of test loading or

test load

Elastic

deformation[mm]

Permanent

deformation[mm]

1 Stacking

Corner post

Transversemember

Bottom siderail

Load of 1.8 RT uni-formly distributedover floor

Vertical load on each corner post848 kN for:

1 A, 1 AA, 1 AAA, 1 AX1 B, 1 BB, 1 BBB, 1 BX1 C, 1 CC, 1 CX

224 kN for 1 D containers.

Pads offset by: 25 mm laterally 38 mm longitudinally

4,5

6 **

6 **

2

3

40 length: 4

30 length: 3

20 length: 3

2Lifting fromthe 4 top cornerfittings

Transversemember

Bottom siderail

Load of 2.0 RT uni-formly distributedover floor.

The lifting load shall be appliedas follows:

vertical: 40 load30 load20 load

60 to horizontal: 10 load

3

40 length: 4

30 length. 3

20 length: 3

3Lifting fromthe 4 bottomcorner fittings

Transversemember

Bottom siderail


The lifting load shall be appliedas follows:

30 to horizontal: 40 37 to horizontal: 30 45 to horizontal: 20 60 to horizontal: 10

3

40 length: 4

30 length: 3

20 length: 3

4 Restraint test(longitudinal)

Bottom siderail


A horizontal load shall be ap-plied through the bottom cornerfittings first towards and thenaway from the anchor points.

vertical: 40 length: 4 30 length: 3 20 length: 3 10 length: 2

horizontal:acc. to ISOstandard 668

5Strength of endwalls includingdoors

See GL con-tainer type testreport

unladen

Internal load uniformly distrib-uted over wall for

40

30

20

10

0 4

length

length

length

length

P,

20 and 10 non-pressurized drybulk containers: 0.6 P

Walls: 9 *

Doors: 6 *

6Strength of sidewalls

See GL con-tainer type testreport

unladenInternal load, uniformly distrib-uted over wall:

0,6 P

40

309

20

107

length

length

length

length

*

*

* The permissible values for permanent deformations shall be applied only if the returns are adequate, i.e. the standard external dimen-sions are not exceeded.

** Maximum permissible deflection below the plane of the corner fitting supports.


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Table 2.3 Principles for container testing (continued)

Scope of type test Measuring

Test procedure Permissible values

No. and/or

designrequirements

pointInternal

loadMethod of test loading or

test load

Elastic

deformation[mm]

Permanent

deformation[mm]

7 Strength of roof Weakest partof roof unladen

300 kg are uniformly distributedover an area of 600 mm 300 mm in the weakest part of the roof.

If hanging cargo is to be trans-ported, the roof shall be rested attwice the design load with aminimum of 2 1490 kg/m

3

8 Strength of floor

Transverse

members in-cluding siderails

Gooseneck-tunnel

unladen

Test vehicle:Test load: 5460 kgWheel base: 760 mmWheel contact area: 142 cm 2 /

per wheel

The test vehicle shall transversethe entire floor area of the con-tainer.

4

5

9Transverse ri-gidity

See GL con-tainer type unladen

150 kN horizontally:

The loads shall be applied firsttowards and then away from thetop corner fittings.

The difference between thechanges in length measureddiagonally shall not exceedthe following values

test report If a test load of 75 kN is used, thedoors are required to be weather-proof.

60 10

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