Designation: D4169 − 16
Standard Practice for
Performance Testing of Shipping Containers and Systems 1 This standard is issued under the fixed designation D4169; the number immediately following the designation indicates the year of original origin al adoption or, in the case of revis revision, ion, the year of last revision. revision. A number in paren parenthese thesess indicates the year of last reappr reapproval. oval. A superscript epsilon (´) indicates an editorial change since the last revision or reapproval. This standard has been approved for use by agencies of the U.S. Department of Defense.
1. Sco Scope* pe*
D999 Test Methods for Vibration Testing of Shipping ConD999 Test tainers D4003 Test D4003 Test Methods for Programmable Horizontal Impact Test for Shipping Containers and Systems D4332 Practic Practicee for Condit Conditioning ioning Containers, Packages, or Packaging Components for Testing D4728 Test D4728 Test Method for Random Vibration Testing of Shipping Containers D5265 Test D5265 Test Method for Bridge Impact Testing D5276 Test D5276 Test Method for Drop Test of Loaded Containers by Free Fall D5277 Test D5277 Test Method for Performing Programmed Horizontal Impacts Using an Inclined Impact Tester D5487 Test D5487 Test Method for Simulated Drop of Loaded Containers by Shock Machines D6055 Test D6055 Test Methods for Mechanical Handling of Unitized Loads and Large Shipping Cases and Crates D6179 Test D6179 Test Methods for Rough Handling of Unitized Loads and Large Shipping Cases and Crates D6344 Test D6344 Test Method for Concentrated Impacts to Transport Packages D6653 Test Metho Methods ds for Determining the Ef Effects fects of High Altitude on Packaging Systems by Vacuum Method D7386 Pra Practic cticee for Per Perfor forman mance ce Testi esting ng of Pac Packag kages es for Single Parcel Delivery Systems F1327 Terminology F1327 Terminology Relating to Barrier Materials for Medical Packaging (Withdrawn Packaging (Withdrawn 2007) 3 2.2 Military Standards:4 MIL-STD-810F Environmental MIL-STD-810F Environmental Test Methods MIL-STD-2073–1 DOD Sta Standa ndard rd Pra Practic cticee for Mili Militar tary y Packaging
1.1 This practice practice provides a uniform uniform basis of evaluating, in a lab labora orator tory y, the abil ability ity of shi shippi pping ng uni units ts to with withstan stand d the distribution environment. This is accomplished by subjecting them to a test plan consistin consisting g of a seq sequen uence ce of anticipate anticipated d hazard elements encou encountered ntered in variou variouss distrib distribution ution cycles. This practice is not intended to supplant material specifications or existing preshipment test procedures. 1.2 Co 1.2 Cons nsid ider er th thee us usee of Pr Pract actice ice D7386 for for tes testin ting g of packages for single parcel shipments. 1.3 The suitabilit suitability y of thi thiss pra practic cticee for use with hazardou hazardouss materials has not been determined. 1.4 The values stated in inch-poun inch-pound d units are to be regar regarded ded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard. standard d doe doess not purport purport to add addre ress ss all of the 1.5 This standar safet sa fetyy co conc ncer erns ns,, if an anyy, as asso socia ciated ted wit with h it itss us use. e. It is th thee responsibility of the user of this standard to establish appro priate safety and health practices and determine the applicability of regulatory limitations prior to use.
2. Referenc Referenced ed Documents Documents 2.1 ASTM Standards: 2 D642 Test D642 Test Method for Determining Compressive Resistance of Shipping Containers, Components, and Unit Loads D880 Test D880 Test Method for Impact Testing for Shipping Containers and Systems D951 Test D951 Test Method for Water Resistance of Shipping Containers by Spray Method D996 Terminology D996 Terminology of Packaging and Distribution Environments
2.3 Association of American Railroads Standards: 5 Generall Info Genera Information rmation Bulletin No. 2 Rules Rules and Proced Procedures ures for Testin Testing g of New Loading Loading and Bracing Bracing Met Method hodss or Materials
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This practice is under the jurisdiction of ASTM Committee D10 Committee D10 on on Packaging and is the direct responsibility of Subcommittee D10.21 Subcommittee D10.21 on on Shipping Containers and Systems - Application of Performance Test Methods. Curren Cur rentt edi edition tion app approve roved d Apr April il 1, 201 2016. 6. Pub Publis lished hed Jun Junee 201 2016. 6. Ori Origin ginall ally y approved in 2004. Last previous edition approved in 2014 as D4169 – 14. DOI: 10.1520/D4169-16. 2 For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at
[email protected]. For Annual Book of ASTM Standards volume information, refer to the standard’s Document Summary page on the ASTM website.
3
The last app approv roved ed ver versio sion n of thi thiss his histor torica icall sta standa ndard rd is refe referen renced ced on www.astm.org. 4 Availab vailable le from Stand Standardiza ardization tion Docum Documents ents Order Desk, DODSSP, Bldg. 4, Secti Se ction on D, 700 Rob Robbin binss Ave. ve.,, Ph Phila iladel delphi phia, a, PA 191 19111 11-50 -5098, 98, htt http:/ p:// / dodssp.daps.dla.mil. 5 Available from Association of American Railroads (AAR), 425 Third St., SW, Washington, DC 20024, http://www.aar.org.
*A Summary of Changes section appears at the end of this standard Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
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D4169 − 16 3. Terminology
3.3.1 TOFC— trailer trailer on flatcar.
3.1 Definitions— General General definitions for the packaging and distribution environments are found in Terminology D996 D996..
3.3.2 COFC— container container on flatcar.
3.2 Definitions of Terms Specific to This Standard: 3.2.1 acceptance criteria— the the acceptable quality level that must be met after the shipping unit has been subjected to the test plan. See Section 7.
3.3.4 CL— carload. carload.
3.3.3 TL— truckload. truckload. 3.3.5 LTL— less less than truckload. 4. Signi Significanc ficancee and Use
3.2.2 assurance level— the the level of test intensity based on its probability of occurring in a typical distribution cycle. 3.2.2.1 Discussion— Level Level I is a high level of test intensity and has a low probability of occurrence. Level III is a low level of test intensity, but has a correspondingly high probability of occurrence. Level II is between these extremes. For Distribution Cycle 18 (DC–18), see MIL-STD-2073–1 for definitions of military levels of protection.
4.1 This pra practic cticee pro provid vides es a gui guide de for the eva evaluat luation ion of shipping shippi ng uni units ts in acco accorda rdance nce with a uni unifor form m sys system, tem, usi using ng establi esta blishe shed d tes testt meth methods ods at lev levels els rep repres resent entativ ativee of tho those se occurring in actual distribution. The recommended test levels aree ba ar base sed d on av avai ailab lable le in info form rmat atio ion n on th thee sh ship ippi ping ng an and d handling environment, and current industry/government practice and experience (1-13 testss sho should uld be per perfor formed med 1-13)).6 The test sequentially on the same containers in the order given. For use as a performance test, this practice requires that the shipping unitt test uni tested ed rem remain ain unopened unopened until the seq sequen uence ce of tes tests ts are comp co mplet leted ed.. If us used ed fo forr ot othe herr pu purp rpos oses, es, su such ch as pa pack ckag agee development, it may be useful to open and inspect shipping units uni ts at var variou iouss time timess thr throug oughou houtt the seq sequen uence. ce. Thi Thiss may may,, howeve how everr, pro prohib hibit it eva evalua luating ting the infl influen uence ce of the con contain tainer er closure on container performance.
coeffıcient ient of rest restitution itution— — the 3.2.3 coeffıc t he ra ratio tio of th thee re rebo boun und d velocity to the impact velocity.
3.2.4 distribution cycle (DC)— the the sequential listing of the testt sc tes sche hedu dule less em empl ploy oyed ed to si simu mulat latee th thee ha haza zard rd ele eleme ment ntss expected to occur for a specific routing of a shipping unit from production to consumption. See Table 1. 1. 3.2.5 feeder aircraft— small, small, potentially non-pressurized aircraft used to transport express packages.
4.2 For Distribution Distribution Cycle 18, as referred to in MIL-STD2073 20 73–1 –1,, th thee us usee of th this is pr prac actic ticee is de defin fined ed in su subs bseq eque uent nt sections identified as DC-18.
hazard elemen element— t— a sp 3.2.6 hazard spec ecifi ificc ev even entt th that at oc occu curs rs in a distribution cycle that may pose a hazard to a shipping unit. The element will usually be simulated by a single test schedule. See Section 9 Section 9..
5. Test Specimen 5.1 Test Test spe specime cimens ns con consis sistt of rep repres resent entativ ativee sam sample pless of complete comple te shipp shipping ing units, includ including ing actual contents. Products with blemishes or minor defects may be used if the defective component is not to be studied by the test and if the defect is documented in the report. Dummy test loads are acceptable if testing the actual product might be hazardous. If a dummy load is used, it should be instrumented to determine if the fragility level of the actual product has been exceeded. Take care to duplica dup licate te the loa load d cha charac racter teristi istics cs of the actu actual al pro produc duct, t, and avoid unnecessary prehandling.
3.2.7 shipping unit— the the smallest complete unit that will be subjec sub jected ted to the dis distri tribut bution ion env enviro ironme nment, nt, for exa exampl mple, e, a shipping container and its contents. 3.2.7.1 small shipping unit— for for DC-18, DC-18, a smal smalll shi shippi pping ng unit is defined as one having no edge dimension or diameter over 60 in. (1.52 m) and a gross weight of 100 lb (45 kg) or less. 3.2.7.2 large for DC-18, DC-18, a lar large ge shi shippi pping ng large shipp shipping ing unit— for unit is defined as one having at least one edge dimension or diameter over 60 in. (1.52 m) or a gross weight in excess of 100 lb (45 kg), or it is one that has a gross weight exceeding 100 lb (45 kg) and is secured to a base or to the base of a shipping unit.
5.2 Car Caree mus mustt be taken to ens ensure ure that no deg degrad radatio ation n has occu oc curr rred ed to eit eithe herr th thee pr prod oduc uctt or th thee pa pack ckag agee if th thee te test st packages have been shipped to the test site. If any doubt exists as to the condition of the package, repack the product in new packaging packag ing material before testing testing..
3.2.8 test plan— a specific listing of the test sequence to be followed to simulate the hazards anticipated during the distributi bu tion on cy cycle cle of a sh ship ippi ping ng un unit. it. In Inclu clude ded d wil willl be th thee tes testt intensity and number of sequential tests to be conducted. See 8.5.. 8.5
5.3 The number of test replications replications depends depends on the desired objec ob jectiv tives es of th thee te testi sting ng an and d th thee av avail ailab abili ility ty of du dupl plica icate te products and shipping containers. Replicate testing is recommended to improve the reliability of the test results.
schedu edule— le— the 3.2.9 test sch t he sp spec ecifi ificc pr proc oced edur uree to be us used ed,, including the three assurance level intensities, and a reference to the test method that is the basis of the schedule. 3.2.9.1 Discussion— The The purpose purpose of the schedule is to simulate the for forces ces occurrin occurring g dur during ing any haz hazard ard element element of the distribution cycle. See Section 9.
6. Condi Condition tioning ing 6.1 If the distribution distribution cycle contains contains climatic conditions conditions that have ha ve an ef effe fect ct on th thee pe perf rfor orman mance ce ch char arac acter terist istics ics of th thee product, shipping container, or components such as cushioning, use one of the following procedures. (It should be noted that different atmospheric conditions are likely to exist between the
3.2.10 total velocity change, (∆V)— the the sum of the impact and rebou rebound nd veloci velocities. ties.
6
The boldface numbers in parentheses refer to a list of references at the end of this practice.
3.3 Abbreviations: 2
D4169 − 16 TABLE 1 Distribution Cycles
DC
Distribution Cycle
Performance Test Schedule Sequence (see Section 9 Section 9 for Test Schedule definition) Third Fourth Fifth
First
S ec o nd
Schedule A Handling
Schedule D Stacke Schedule Stacked d Vibration
1
Generall Cyc Genera Cycle— le—und undefin efined ed dis distri tribut bution ion system
Schedule Schedu le F Loose-Load Vibration
2
Specially Specia lly defi defined ned dis distri tribut bution ion sys system tem,, user specified (see Appendix X2)
3
Single pac Single packag kage e wit withou houtt pal pallet let or ski skid, d, LTL motor freight
4
Sing Si ngle le pa pack ckag age e wi with th pa pall llet et or sk skid id,, LTL motor freight
5
Motor freight, TL, not unitized
S c h e du l e A Handling
Schedule D Stacke Schedule Stacked d Vibration
6
Motor freight, TL, or LTL—unitized
S c h ed u l e A Handling
Schedule D Stacke Schedule Stacked d Schedu Schedule le J Vibration OR Concentrated Schedule C Vehicle Impact Stacking plus Schedule E Vehicle Vibration
7
Rail only, bulk loaded
S c he d ul e A Handling
Schedule D Stacke Schedule Stacked d Vibration
8
Rail only, unitized
S c he d ul e A Handling
9
Rail and motor freight, not unitized
10
Schedule G Schedu Schedule Schedule le J Rail Concentrated Switching Impact
S i x th
S ev e nt h
Schedule A Handling
select from Schedules A through I
Schedule Schedule Schedule D Stacke Stacked d A Vibration OR Handling Schedule C Vehicle —Manual Stacking plus Schedule E Vehicle Vibration
Schedule Schedu le F Schedule Schedu le J Loose-Load Concentrated Vibration Impact
Schedule A Handling— Manual
...
Schedule Schedule Schedule D Stacke Stacked d A Vibration OR Handling Schedule C Vehicle —Mechanical Stacking plus Schedule E Vehicle Vibration
Schedule Schedu le F Schedule Schedu le J Loose-Load Concentrated Vibration Impact
Schedule A Handling— Mechanical
...
Schedule E Schedule Schedule Schedu le J Vehicle Concentrated Vibration Impact
Schedule A Handling
...
Schedule A Handling
Schedule B Schedule Warehouse Stacking
...
Schedule G Schedule Rail Switching
Schedule A Handling
...
...
Schedule D Stacke Schedule Stacked d Vibration
Schedule G Schedule Rail Switching
Schedule A Handling
Schedule B Schedule Warehouse Stacking
...
S c h ed u l e A Handling
Schedule C Vehicle Stacking
Schedule E Schedule Vehicle Vibration
Schedule G Schedule Rail Switching
Schedule Schedu le F Loose-Load Vibration
Schedule Schedu le J Concentrated Impact
Rail and motor freight, unitized
S c he du l e A Handling
Schedule D Stacke Schedule Stacked d Vibration
Schedule G Schedu Schedule Schedule le J Rail Concentrated Switching Impact
Schedule A Handling
Schedule B Schedule Warehouse Stacking
11
Rail, TOFC and COFC
S c h e du l e A Handling
Schedule G Rail Switching
Schedule D Schedule Stacked Vibration
Schedule Schedu le F Loose-Load Vibration
Schedule A Handling
...
12
Air (in (inter tercit city) y) and mot motor or fre freigh ightt (lo (local cal), ), over 150 lb (68.1 kg), or unitized
Schedule A Handling
Schedule D Stacke Schedule Stacked d Vibration
Schedule I Schedule Low PressureA
Schedule E Schedu Schedule Schedule le J Vehicle Concentrated Vibration Impact
Schedule A Handling
13
Air (in (inter tercit city) y) and mot motor or fre freigh ightt (lo (local cal,, single package up to 150 lb (61.8 kg). Consider using Practice D7386 Practice D7386 for single parcel carrier shipments.
Schedule A Handling
Schedule C Vehicle Stacking
Schedule Schedu le F Loose-Load Vibration
Schedule I Schedule Low PressureA
Schedule E Schedule Vehicle Vibration
Schedule J Schedule Concentrated Impact
14
Warehous Wareh ousing ing (pa (parti rtial al cyc cycle le to be add added ed to other cycles as needed needed))
Schedule A Handling
Schedule B Warehouse Stacking
...
...
...
...
15
Export/Im Export /Impor portt shi shipme pment nt for int interm ermoda odall container contai ner or roll on/roll off trailer (partial cycle to be added to other cycles as needed)
Schedule A Handling
Schedule C Vehicle Stacking
Schedule A Handling
...
...
...
3
Schedule A Handling
Schedule A Handling
D4169 − 16 TABLE 1 Continued
DC
Distribution Cycle
First
S ec o nd
Performance Test Schedule Sequence (see Section 9 Section 9 for Test Schedule definition) Third Fourth Fifth
S i x th
16
Export/Im Export /Impor portt shi shipme pment nt for pal pallet letize ized d car cargo go ship (partial cycle to be added to other cycles as needed needed))
Schedule A Handling
Schedule C Vehicle Stacking
Schedule A Handling
...
...
...
17
Export/Im Export /Impor portt shi shipme pment nt for bre break ak bul bulk k cargo ship (partial cycle to be added to other cycles as needed)
Schedule A Handling
Schedule C Vehicle Stacking
Schedule A Handling
...
...
...
18
Non-Commercial Government shipments per MIL-STD-2073-1
S ev e nt h
Refer to to Annex Annex A1 A1 for Test Schedules applying to DC-18.
A
This high altitu altitude, de, non-pressurized non-pressurized transport transport simula simulation tion test may be delete deleted d from this distri distribution bution cycle when testin testing g shippi shipping ng units that contain primary packages that have a porous material.
7.2 In ma 7.2 many ny ca case ses, s, th thee ac acce cept ptan ance ce cr crit iter eria ia ca can n be th thee following: Criterion 1—Product is damage-free. Criterion 2—Package is intact. Criterion 3—Both criteria 1 and 2. Often, this means that the shipping container and its contents are suitable for normal sale and use at the completion of the test cycle. cyc le. Det Detaile ailed d acc accepta eptance nce cri criteri teriaa may allo allow w for acce acceptin pting g specified damage to a product or its package. The form and content of acceptance criteria may vary widely, in accordance with the particular situation. Methods may range from simple pass-fail judgments to highly quantitative scoring or analysis systems.
origin and destination points of a distribution cycle, particularly for export/import cycles.) 6.1.1 Condu Conduct ct the test at standa standard rd conditions conditions and compe compennsate for the ef effec fects ts of any climatic climatic con condit dition ion.. Con Condit dition ion the shipping units to a standard atmosphere of 73.4 6 2°F (23 6 1°C) and 50 6 2 % relative humidity. Condition fiberboard contain con tainers ers in acco accorda rdance nce with Pra Practic cticee D4332. D4332. Th Thee sa same me atmospheric condition should be used for any assurance level. A condition conditioning ing period period of 72 h, or suf suffficie icient nt time to rea reach ch equilibrium of all parts of the package and product is recommended. Tests should be conducted in the conditioned atmosphere whenever possible. If not possible, conduct the tests as soon so on af after ter re remo mova vall fr from om th thee co cond nditi ition onin ing g at atmo mosp sphe here re as practic pra cticabl able. e. Reco Recondi ndition tion the shi shippi pping ng uni units ts to the stan standar dard d atmosphere as necessary during the test plan. 6.1.2 In some circumstances, it may be be necessary to conduct some or all of the tests at special climatic conditions, such as those given in Practice D4332 Practice D4332,, or Test Method D951 Method D951,, or others (salt, spray, water immersion, humidity, or temperature). The same climatic condition should be used for any assurance level. A con conditi ditioni oning ng per period iod sho should uld be pro provid vided ed whi which ch will allo allow w sufficient time to reach equilibrium of all parts of the package and pro produc duct. t. Test estss sho should uld be con conduc ducted ted in the con condit dition ioned ed atmosph atmo sphere ere whe whenev never er pos possib sible. le. If not pos possib sible, le, con conduc ductt the tests as soon after removal from the conditioning atmosphere as pra practic cticabl able. e. Reco Recondi ndition tion the shi shippi pping ng uni units ts as nec necess essary ary during the test plan. For atmospheres other than the standard conditioning atmosphere, the user must determine the appropriate pri ate com compre pressiv ssivee loa load d fact factor or for war wareho ehouse use and veh vehicle icle stacking, as the factors given in 11.2 in 11.2 are are based on testing under the standard test atmosphere.
8. Pro Procedu cedure re 8.1 Define Shipping Unit— Describe Describe shipping unit in terms of size, weight, and form of construction. See 3.2.7 See 3.2.7.. Determine wheth wh ether er th thee co cont ntai aine nerr wi will ll be ma manu nuall ally y or me mech chan anica ically lly handled. Establish h Ass Assura urance nce Leve Level— l— Spec 8.2 Establis S pecif ify y a le leve vell of te test st intens int ensity ity.. The leve levell sho should uld be one of thr three ee pre pre-es -establ tablish ished ed assura ass urance nce lev levels. els. This mus mustt be pre pre-es -estab tablish lished ed bas based ed on the product value, the desired level of anticipated damage that can be tolerated, the number of units to be shipped, knowledge of the shipping environment, or other criteria. Assurance Level II is sugge suggested sted unless conditions conditions dictate otherwise. Assurance Assurance Level I provides a more severe test than II. Assur Assurance ance Level III provides a less severe test than II. The assurance level may be varied var ied bet between ween sch schedu edules les (se (seee Sec Sectio tions ns 10 – 15) 15 ) if such such variations are known to occur. The test levels used should be reported. See Section 18 18..
7. Acceptance Criteria
8.3 Determi Acceptance criteria Determine ne Acce Accepta ptance nce Crit Criteria eria— — Acceptance are related to the desired condition of the product and package at the end of the distribution cycle. See Section 7.
7.1 Accep Acceptance tance criteria must be established prior prior to testing and should consider the required condition of the product at receipt. The organizations conducting the test may choose any acceptance criteria suitable for their purpose. It is advisable to compare the type and quantity of damage that occurred to the test specimens specimens with the dam damage age tha thatt occ occurs urs during during actu actual al distribution and handling or with test results of similar containers whose shipping history is known.
8.4 Select Distribution Cycle— Select Select a Distribution Cycle from fro m the ava availab ilable le sta standa ndard rd dis distri tribut bution ion cyc cycles les com compil piled ed in Table 1. Use th thee DC th that at mo most st clo close sely ly co corr rrela elates tes wi with th th thee projected distribution. When the distribution is undefined, the general distribution cycle DC-1 should be selected. When the 4
D4169 − 16 anticipated distribution is well understood, a special distribution cycle DC-2 may be specified. In using DC-2, the user selects sele cts test sch schedu edules les fro from m Sec Sectio tion n 9 and spe specifie cifiess the test sequence (see Appendix (see Appendix X2 for X2 for more details). For purposes of DC-3 and DC-13, the bottom of a single package is the surface on which the package rests in its most stable orientation. The identified bottom should be utilized for purposes of determining the starting orientation of each test schedule within the above stated distribution cycles.
system that will be handled by mechanical means. Manual and mechanical handling are described further in 10.2 and and 10.3 10.3.. 10.2 Manual Handling— The The test levels and the test method for this sch schedu edule le of the dis distrib tributio ution n cyc cycle le are int intend ended ed to determ det ermine ine the ability of the shi shippi pping ng uni unitt to with withsta stand nd the hazards occurring during manual handlings, such as loading, unloading, stacking, sorting, or palletizing. The main hazards from these operations are the impacts caused by dropping or throwi thr owing. ng. Size, weig weight, ht, and shape of the shi shippi pping ng uni unitt will affe af fect ct th thee in inten tensit sity y of th these ese ha hazar zards ds.. Se Seve vera rall tes testt me meth thod od options are permitted, including free fall and simulated drop test using shock machines. While these test methods produce similar sim ilar res result ults, s, the sho shock ck mac machin hinee met method hod pro produc duces es mor moree control of orientations of impact; see Test Method D5487 for limitations of the shock machine method. 10.2.1 10. 2.1 For lon long g nar narrow row pac packag kages es tha thatt are mec mechan hanical ically ly sorte so rted, d, an anot othe herr ha haza zard rd to be si simu mulat lated ed is br brid idge ge im impa pact ct (10.2.4 10.2.4). ). 10.2.2 10.2. 2 Mechan Mechanical ical handling handling (10.3 ( 10.3)) may be used when it is anticipated that handling will be by mechanical means only. 10.2.3 10. 2.3 For the fre free-f e-fall all and sho shock ck mach machine ine tes tests, ts, rec recomommended drop heights, the number of drops, the sequence of drop dr ops, s, an and d th thee sh ship ippi ping ng un unit it or orien ientat tatio ion n at im impa pact ct ar aree as follows: Test Method D5276 Method D5276,, D5487 D5487.. Conditioning—See Section 6.
Writee Test Pla Plan— n— Prep 8.5 Writ P repar aree a te test st pl plan an by us usin ing g th thee sequen seq uence ce pre presen sented ted in Tab Table le 1 for for the dis distri tribut bution ion cyc cycle le selected. Obtain the test intensities from the referenced schedules. The test plan intensity details must take into account the assurance levels selected as well as the physical description of the shipp shipping ing unit. Table 1 thus leads to a detailed test plan consisting of the exact sequence in which the shipping unit will be subjected to the test inputs. The test schedules associated with each element reference the existing ASTM test methods for clarification of the equipment and techniques to be used to conduct the test. 8.5.1 Sample test plans are provided provided in Appendix in Appendix X1. X1 .
8.6 Select Samples for Test— See See Section 5 Section 5.. 8.7 Condition Samples— See See Section 6. 8.8 Perform Tests— Perform Perform tests as directed in reference ASTM AS TM st stan anda dard rdss an and d as fu furth rther er mo modi difie fied d in th thee sp spec ecial ial instructions for each test schedule. 8.9 Evaluate Results— Evaluate Evaluate results to determine if the shipping units meet the acceptance criteria. See Section 7.
Shipping Weight, lb (kg) 0 to 20 (0 to 9.1) 20 to 40 (9.1 to 18.1) 40 to 60 (18.1 to 27.2) 60 to 80 (27.2 to 36.3) 80 to 100 (36.3 to 45.4) 100 to 200 (45.4 to 90.7)
8.10 Document Test Results— Document Document test results by reporting each step. See Section 18 18.. Shipments— ents— When 8.11 Monitor Shipm When possible, obtain feedb feedback ack by monitoring shipments of the container that was tested to ensure that the type and quantity of damage obtained by the laboratory testing correlates with the damage that occurs in the distrib dis tributio ution n cyc cycle. le. Thi Thiss inf inform ormatio ation n is ver very y use useful ful for the planning of subsequent tests of similar shipping containers.
Number of Impacts Impact s at Specified Height
9. Haza Hazard rd Elements Elements and Test Test Schedules Schedules
One Two Two Tw o
9.1 Hazard Elements Elements and Test Test Schedules are categorized categorized as follows: S c h ed u l e A B C D E F G H I J
Hazard Element Handling— Handli ng—man manual ual and mec mechan hanica icall Warehouse Stacking Vehicle Stacking Ve S tacked Vibration St Vehicle Vibration Ve Loose Load Vibration Rail Switching Environmental Hazard Low Pressure Hazard Concentrated Impact
One
Test S e c ti o n drop, imp drop, impact act,, sta stabil bility ity 10 compression 11 compression 11 vibration 12 vibration 12 repetitive shock 13 l o n g i tu d i n a l s h o c k 14 cyclic exposure 15 v ac uum 16 i m pa c t 17
Number of Impacts Impact s at Specified Height One Two Two
10. Schedule A—Handling—Manua A—Handling—Manuall and Mechanical:
One
10.1 There 10.1 There ar aree two ty type pess of ha hand ndlin ling g ha haza zard rd ele eleme ment nt,, manual and mechanical. The manual handling test should be used for single containers, containers, smaller packag packages, es, and any shipping container that can be handled manually, up to a weight of 200 lb (90.7 kg). Mechanical handling should be used for unitized loads, large cases and crates, and any shipping container or
24 21 18 15 12 10
Drop Height, in. (mm) Assurance Level I II I II (610) 15 (381) 9 (229) (533) 13 (330) 8 (203) (457) 12 (305) 7 (178) (381) 10 (254) 6 (152) (305) 9 (229) 5 (127) (254) 7 (178) 4 (102)
Impact Orientation First Sequence of Distribution Cycle Box to p adja ad jace cent nt bo bott ttom om ed edge ges s diagon dia gonall ally y opp opposi osite te bot bottom tom corners b o t to m
B a g or S ac k fa c e two tw o si side des s both bo th en ends ds
Cylindrical Container t op two tw o si side des s 90 90°° ap apar artt bott bo ttom om ed edge ges s 90 90°° ap apar artt
o p p o s i t e fa c e
b o t to m
Impact Orientation Second Sequence of Distribution Cycle Box vertical edge a d j a c e n t s i d e fa c e s one on e top top co corn rner er an and d one one adjacent top edge see Note 1
B a g or S ac k f ac e two sides both bo th en ends ds
Cylindrical Container t op two sides 90° apart bott bo ttom om ed edge ges s 90 90°° ap apar artt
see Note see Note 1
see Note see Note 1
NOTE 1—On the last impact of the last manual handling sequence in a distribution cycle, the impact should be made at twice the specified height or equ equiva ivalen lentt velo velocity city change. change. (Th (This is is the fina finall (si (sixth xth)) dro drop p in the sequen seq uence, ce, not an add additio itional nal dro drop.) p.) The dro drop p sho should uld be in the impact impact orientation most likely for a drop to occur, usually the largest face or the bottom. For distribution cycles where any drop orientation is possible (that is, shipments shipments via carriers that mecha mechanically nically sort packages), packages), this drop
5
D4169 − 16 Test Method —D880 D880,, D4003 D4003,, D6055 D6055,, D6179 D6179.. Conditioning—See Section 6. 10.3.2.1 All Methods of Truck Handling— Pick Pick up, transport around aro und test cou course rse,, and set dow down n in acco accorda rdance nce wit with h Test Methods D6055 Methods D6055,, Method A for fork lift, Method B for spade lift, Method C for clamp, and Method D for pull pack.
should be in the most critical or damage-prone orientation, as defined in Test Method D5276 Method D5276.. NOTE 2—The equivalent velocity change corresponding to the specified drop height used for the shock machine method shall be calculated as specified in Test Method D5487 Method D5487..
10.2.4 Bridge Impact Test: Test Method— D5265. D5265. Conditioning— See See Section 6. 10.2.4.1 10.2. 4.1 Condu Conduct ct bridg bridgee impacts on long, narrow shipping units which have a length of at least 36 in. (915 mm) and each of the other two dimensions are 20 % or less of the longest dimension. 10.2 10 .2.4 .4.2 .2 Th These ese tes tests ts ar aree re requ quir ired ed on only ly on once ce in an any y tes testt schedule sequence.
Assurance Level I II III
(1) For shipments via less-than-truckload (LTL), simulate transfer terminal handling by performing fork lift truck transport po rt ov over er a flo floor or ha haza zard rd de desc scri ribe bed d as fo foll llow ows: s: a mo modi difie fied d nominal 2 by 6 in. board with one edge beveled full height at 45° (see Fig. 1) 1) shall be placed on the course in a position where both lift truck wheels on one side must pass over it during each handling sequence, and a second modified nominal 2 by 6 in. board shall be placed on the course after the 90° turn in such a position that both lift truck wheels on the opposite side must pass over it during each handling sequence.
Mechanical Handl Handling— ing— The 10.3 Mechanical T he tes testt lev level elss an and d th thee tes testt method for this schedule of the distribution cycle are intended to det determ ermine ine the abi ability lity of lar large ge and heavy shipping shipping units, singl sin glee pa pack ckag ages es wi with th pa palle llett or sk skid id,, an and d un uniti itize zed d lo load adss to withstand the mechanical handling hazards that occur during loading load ing,, unl unload oading ing,, sor sortin ting, g, or stac stackin king. g. For lar large ge shi shippi pping ng cases and crates and any single package with pallet or skid, different test methods are used versus unit loads. For various types of unit loads, test methods also vary, depending on the method of truck handling: fork, clamp, spade, or pull/pack. 10.3.1 Large Shipping Cases and Crates and Single Packages ag es wit with h Pa Palle llett or Sk Skid id— — Perf P erfor orm m th thee fo follo llowin wing g tes testt se se-quences: Test Method —D6179 D6179,, D880 D880,, D4003 D4003.. Conditioning—See Section 6 Section 6.. 10.3.1.1 Fork Lift Truck Handling— One One rotational flat drop from each opposite base edge in accordance with Method C of Test Methods D6179 and one rotational drop on each of two diagonally opposite base corners in accordance with Method B of Test Methods D6179 D6179.. Gross Weight, lb (kg) 0 to 500 (0 to 226.8) Over 500 (226.8)
10.3.2.2 All Methods of Truck Handling— Impact Impact all four sides of the shi sides shippi pping ng uni unitt in acc accord ordanc ancee wit with h Test Met Method hod D880 Proced Procedure ure B. Alte Alterna rnately tely,, use Test Met Method hod D4003, D4003, Method B using a short duration programmer, assuming the coefficient of restitution is 0.0 and the total velocity change is equivalent to the specified impact velocity. Assurance Level I II III
Impact Velocity ft/s(m/s) 5.75 (1.75) 4.0 (1.22) 3.0 (0.91)
10.3.2.3 Fork Lift Truck Handling— One One rotational flat drop from each opposite base edge in accordance with Method C of Test Methods D6179 Methods D6179.. Gross Weight, lb (kg) 0 to 500 (0 to 226.8) Over 500 (226.8)
Drop Height, in. (mm) Assurance Level I II I II 12 (305) 9 (229) 6 (152) 9 (229) 6 (152) 3 (076)
Drop Height, in. (mm) Assurance Level I II III 12 (305) 9 (229) 6 (152) 9 (229) 6 (152) 3 (76)
11. Schedule B—Warehouse B—Warehouse Stacking and Schedule C—Vehicle Stacking:
10.3.1.2 Crane Handling— (Conduct (Conduct this test only if cranes are used for handling in the distribution process.) One drop flat on bo bott ttom om an and d on onee dr drop op on ba base se ed edge ge in acc accor orda danc ncee wi with th Method D of Test Methods D6179 Methods D6179.. Use the same drop heights versus shipping unit weight as in 10.3.1.1 10.3.1.1.. Side Imp Impact act Test— Impa 10.3.1.3 Side I mpact ct all fo four ur si side dess of th thee shipping unit in accordance with Test Method D880 D880,, Procedure B. Altern Alternately ately,, use Test Test Metho Method d D4003 D4003 Method Method B using a short duration programmer, assuming the coefficient of restitution is 0.0 and the total velocity change is equivalent to the specified impact velocity. Assurance Level I II I II
Cycles (Round Trips) 8 5 3
11.1 The test levels and the test methods for these schedules 11.1 schedules of a distribution cycle are intended to determine the ability of the shipping unit to withstand the compressive loads that occur during durin g wareh warehouse ouse storage or vehicle transport. transport. The requi required red loading must consider the effects of length of time in storage, the alignment or stacking pattern of the container, variability in container contai ner streng strength, th, moistu moisture re conten content, t, temper temperature, ature, previous handlin han dling g and tra transp nsport ortatio ation, n, met method hod of loa load d sup suppor port, t, and vibration. vibra tion. The minimu minimum m requi required red loads for typical shipp shipping ing
Impact Velocity ft/s(m/s) 5.75(1.75) 4.0(1.22) 3.0(0.91)
Tip Test— In 10.3.1.4 Tip In acco accorda rdance nce with Met Method hod F of Test Methods D6179 Methods D6179.. 10.3.1.5 Tipover Test— In In accordance with Method G of Test Methods D6179 Methods D6179 if shipping unit fails Tip Test above. Unitized Load Loads— s— Perf 10.3.2 Unitized P erfor orm m th thee fo follo llowi wing ng tes tests ts se se-quences as appropriate for the method of truck handling:
FIG. 1 Floor Hazard
6
D4169 − 16 units which include the combined effects of the above factors are recommended below for Schedule B—Warehouse Stacking and Schedule C—Vehicle Stacking (select test levels for either wareho war ehouse use or veh vehicle icle sta stackin cking g as defi defined ned in the dis distri tribut bution ion cycle): Test Method D642. D642. Conditioning—73.4 6 2°F (23 6 1°C), 1°C), 50 6 2 % rel relativ ativee humidity in accordance with Practice D4332 Practice D4332..
load the shipping unit to the computed load value, as calculated below. Remove the load within 3 s after reaching the specified value. val ue. If the ave averag ragee shi shippi pping ng den densit sity y fac factor tor (Mf ) fo forr th thee specific distribution system is not known, use a value of 10 lb/ft (160 kg/m3). 3
L 5 M f
where: = L M f = J = H =
11.2 11 .2 Use the following test levels: F Factors Assurance Level Schedule Schedule B—Warehouse C—Vehicle Shipping Unit Construction I II III I II I II 1. Corrugated, fiberboard, or plastic container 8.0 4.5 3.0 10.0 7.0 5.0 that may or may not have stress–bearing interior packaging using these materials, and where the product does not support any of the load. 2. Corrugated, fiberboard, or plastic container 4.5 3.0 2.0 6.0 4.5 3.0 that has stress-bearing interior packaging packag ing with rigid inserts such as wood. 3. Containers constructed of materials other 3 .0 2 .0 1 . 5 4 .0 3 . 0 2 .0 than corrugated, fiberboard, or plastic that are not temperature temperature or humidity sensitive sensit ive or where the produc productt suppor supports ts the load directly, for example, compression package. 4. If the product supports a known portion of the load, the F the F factor factor is calculated in the following manner:
F 5 P ~ F p ! 1 C ~ F c !
(1 )
3 F
=
w K F
= = =
H 2 h h
3 F
(3 )
computed comput ed load load,, lbf lbf or or N, N, shipping shipp ing density density factor factor,, lb/ft lb/ft3 or kg/m3, 1 lbf lbf/lb /lb or 9.8 N/k N/kg, g, maximum maximu m height height of stack stack in transit transit vehicle (if vehicle vehicle stack height is unknown, use 108 in.(2.7 m)), in. or m, see Note see Note 3, 3, heightt of shipping heigh shipping unit unit or individua individuall container, container, in. in. or m, length of shipping shipping unit or or individual individual container container,, in. or m, width of shippin shipping g unit unit or indivi individual dual contain container er,, in. or or m, 3 3 3 3 1728 17 28 in in.. /ft or 1 m /m , and a fa fact ctor or to ac acco coun untt fo forr th thee co comb mbin ined ed effe effect ct of th thee individual factors described above.
12.1 The test levels and test metho methods ds for these distribution distribution cycles are intended to determine the shipping units ability to withstand the vertical vibration environment during transport and the dynam dynamic ic compr compression ession forces resulting from vehicle stack st ackin ing. g. Th Thee te test st lev level elss an and d met metho hods ds acc accou ount nt fo forr th thee magnitude, frequency range, duration and direction of vibration. Select the Schedule D—Stacked Vibration or Schedule E—Vehi E—V ehicle cle Vibr ibratio ation n (no stac stackin king) g) tes testt as defi defined ned by the distribution cycle. Test methods for sine and random vibration are permitted testing options. options. The two methods are not equiv equivaalentt and will not necessari len necessarily ly pro produc ducee the same res result ults. s. The random ran dom test met method hod results results in a bet better ter simulatio simulation n of actu actual al transport vibration environments, and is the preferred method for qualification. The sine test method is often used as a means of determining and observing system resonances and can be used in conjunction with the random method.
11.3 11 .3 For warehouse warehouse stacking and vehicle stacking made up of id iden entic tical al sh ship ippi ping ng un units its,, lo load ad th thee sh ship ippi ping ng un unit it to th thee computed load value, as calculated below. Remove the load within 3 s after reaching the specified value. h
l
K
3
12. Schedule D—Stacked D—Stacked Vibration Vibration and Schedule E—Vehicle Vibration:
If a full pallet load is tested, F factors may be reduced by 30 %.
H 2 h
=
l 3w 3h
NOTE 3—The value for H , when unknown, is reduced to 54 in. (1.4 m) from 108 in. (2.7 m) for packag packages es under 30 lb (13.6 kg) and 2.0 ft3 (0.056 3 m ) or less in size when applied to a vehicle stacking hazard element in LTL shipments.
where: F p = factor given given above above for compress compression ion package package (construc(construction Type 3), P = fractio fraction n of load suppo supported rted by by product, product, F c = fact factor or gi give ven n ab abov ovee fo forr ap appr prop opri riat atee co cont ntai aine nerr construction, and C = fractio fraction n of load load suppor supported ted by contai container ner..
L 5 M 3 J
h
3 J
(2 )
where: L = com comput puted ed load load,, lbf lbf or N, M = mass of one one shipping shipping unit unit or individua individuall container, container, lb or kg, lbf/lb lb or 9.8 N/k N/kg, g, J = 1 lbf/ maximum m height height of stack in storage storage or or transit transit vehicle vehicle (if H = maximu vehicle stack height is unknown, use 108 in.(2.7 m)), in. or m, h = heigh heightt of shipping shipping unit or or individual individual container container,, in. or m, and F = a fa facto ctorr to accoun accountt fo forr th thee co comb mbin ined ed effe effect ct of the individual indiv idual factor factorss descr described ibed above above..
Schedule le D—St D—Stacked acked Vibra ibration— tion— Perfor 12.2 Schedu P erform m the tes testt along the vertical axis with the load in the normal shipping orientation or with the predetermined bottom orientation (as speci sp ecifie fied d in DC DC-3 -3)) fa facin cing g do down wn.. It is pe perm rmis issi sibl blee to us usee a concentrated dead load to simulate an upper unit load or mixed commodities. The concentrated load may be calculated from the formulas in 11.3 in 11.3 and and 11.4 11.4,, with the F factor set equal to 1. Recommended intensities and durations for the random tests are given in 12.4 in 12.4,, and those for sine tests are given in 12.5 12.5.. E—Vehicle ehicle Vibra Vibration— tion— Perfor 12.3 Schedule E—V Perform m the test for each possible shipping orientation (up to three axes). Recommended intensities and durations for the random tests are given in 12.4 in 12.4,, and those for sine tests are given in 12.5 12.5..
11.4 For vehicle stacking 11.4 stacking made up of mixed commodities and shipped in an LTL or small package delivery environment, 7
D4169 − 16 12.4 Random Test Option: Test Method D4728. D4728. Conditioning—See Section 6. 12.4.1 12.4. 1 The power spectral spectral densities densities in Tables in Tables 2-4, 2-4, as defined by the their ir mo mode de of tra trans nspo port, rt, fr freq eque uenc ncy y an and d am ampl plitu itude de breakpoints, and test durations are recommended. 12.4.1.1 12.4. 1.1 Condu Conducting cting the Truck Profile test is recom recommended mended for Distribution Cycles 1, 3, 4, 5 and 6. 12.4.1.2 12.4. 1.2 Condu Conducting cting the Rail Profile test is recom recommended mended for Distribution Cycles 7, 8 and 11. 12.4.1.3 12.4. 1.3 A 60 min test using the Truck Truck Profile followed followed by a 12 120 0 mi min n tes testt us usin ing g th thee Rai Raill Pr Profi ofile le is re reco comm mmen ende ded d fo forr Distribution Cycles 9 and 10. 12.4.1.4 12.4. 1.4 A 60 min test using the Truck Truck Profile followed followed by a 12 120 0 mi min n tes testt us usin ing g th thee Ai Airr Pr Profi ofile le is re reco comm mmen ende ded d fo forr Distribution Cycles 12 and 13. 12.4 12 .4.2 .2 If mo more re de deta taile iled d in info form rmat atio ion n is av avail ailab able le on th thee transport vibration environment or the shipping unit damage history, it is recommended that the procedure be modified to use suc such h inf inform ormatio ation. n. The test time req requir uired ed to rep reprod roduce uce shipping damage is dependent on the mode of failure, as well as the vibration level. Test durations ranging from 30 min to 6 h have been used successfully for different product or package types. A 3 h (180 min) duration is reasonable to use in the absence of specific shipping or testing experience.
12.4.2.1 For the Truck 12.4.2.1 Truck Profile test, it is recom recommended mended to use a combination of all three Test Levels (low, medium, and high) for a better simulation of actual truck vibration environments. The Truck test should be performed in a 1 h (60 min) loop that can be repeated for longer duration simulations. The recommended test durations for the random vibration truck profile are as follows: (1) Low Level for 40 minutes. (2) Medium Level for 15 minutes. (3) High Level for 5 minutes. 12.4.2 12. 4.2.2 .2 For vehicle vehicle vib vibrat ration ion tests whe when n mor moree tha than n one shipping orientation is possible, the total duration should be distributed evenly between the orientations tested. NOTE 4—When conducting the Truck Profile, Assurance Levels I, II, and III are not used.
12.5 Sine Test Option: Test Methods D999, D999, Method B or C. Conditioning—See Section 6. Special Instructions—Dwell time is for each noted product or package resonance up to four discrete resonances. If more than tha n fou fourr res resona onance ncess are not noted, ed, tes testt at the fou fourr fre freque quencie nciess where the greatest response is noted. In frequency sweeps it is advisable to consider the frequency ranges normally encountered ter ed in th thee ty type pe of tr tran ansp spor orta tatio tion n be bein ing g co cons nsid ider ered ed.. Th Thee
TABLE 2 TRUCK—Power Spectral Density Levels Frequency 1 3 4 6 12 16 25 30 40 80 1 00 2 00 Overall Grms
Power Spectr Spectral al Densit Density y Level, G2 /Hz M e d i u m Le v el 0 .0 0 0 7 2 0. 01 8 0. 01 8 0 .0 0 0 7 2 0 .0 0 0 7 2 0. 00 3 6 0. 00 3 6 0 .0 0 0 7 2 0. 00 3 6 0. 00 3 6 0. 00 0 36 0 .0 0 0 0 1 8 0 .5 4
High Level 0 .0 0 0 7 2 0 .0 3 0 0 .0 3 0 0. 00 1 2 0 .0 0 1 2 0 .0 0 6 0 0 .0 0 6 0 0 .0 0 1 2 0 .0 0 6 0 0 .0 0 6 0 0. 00 0 60 0 .0 0 0 0 3 0 0 .7 0
8
L o w L ev e l 0. 00 0 4 0 .0 1 0 0 .0 1 0 0 .0 0 0 4 0 0 .0 0 0 4 0 0 .0 0 2 0 0 .0 0 2 0 0 .0 0 0 4 0 0 .0 0 2 0 0 .0 0 2 0 0 .0 0 0 2 0 0 .0 0 0 0 1 0 0 .4 0
D4169 − 16 TABLE 3 RAIL—Power Spectral Density Levels Frequency 1 2 50 90 2 00 Overall Grms
I 0 .0 0 0 0 2 0 .0 0 2 0 .0 0 2 0. 00 08 0. 00 0 02 0 .4 1
Power Spectral Density Level G2 /Hz Assurance Level II 0. 00 0 01 0 .0 0 1 0 .0 0 1 0 .0 0 0 4 0 .0 0 0 0 1 0 .2 9
I II 0 .0 0 0 0 0 5 0 .0 0 0 5 0. 00 0 5 0 .0 0 0 2 0. 00 0 00 5 0 .2
TABLE 4 AIR—Power Spectral Density Levels Power Spectral Density Level G2 /Hz Assurance Level II 0 .0 0 0 2 0 .0 1 0 .0 1 0. 00 0 01 1 .0 5
Frequency 2 12 10 0 30 0 Overall Grms
I 0 .0 0 0 4 0. 02 0 .0 2 0 .0 0 0 0 2 1 .4 9
resonant frequency(ies) may shift during test due to changing characteristics of the container system. It is suggested that the dwell frequency be varied slightly during the test to detect any
III 0. 00 01 0 .0 0 5 0. 00 5 0 .0 0 0 0 0 5 0 .7 4
shift and to con shift continu tinuee tes testing ting at the fre freque quency ncy of max maximu imum m response. Use the following test levels:
9
D4169 − 16 Assurance Level I II II I
Frequency Range, Hz 3 t o 10 0 3 t o 10 0 3 to 1 0 0
Amplitude (O-Peak), g (O-Peak), g Rail Truck 0 .2 5 0 .5 0 .2 5 0 .5 0 .2 5 0 .5
deemed to be most sensitive to damage. For the fourth impact, rotate the specimen 180° on the carriage.
Dwell Time, min 15 10 5
Assurance Level I
Impact Number 1 2 3 4 (rotate 180°)
II
1 2 3 4 (rotate 180°)
13. Schedule F—Loose Load Vibration: Vibration: 13.1 The test levels and the test method method for this schedule schedule of the distribution cycle are intended to determine the ability of the shipping unit to withstand the repetitive shocks occurring during transportation of bulk or loose loads. The test levels and test method account for amplitude, direction, and duration of the repetitive shocks.
4 6 8 8
(m/s) 1.79 (± 0.22) 2.68 (± 0.22) 3.58 (± 0.22) 3.58 (± 0.22)
4 6 6 6
(± (± (± (±
1 .7 9 2. 68 2. 68 2. 68
0. 5) 0 .5 ) 0 .5 ) 0. 5)
(± (± (± (±
0 .2 2 ) 0. 22 ) 0. 22 ) 0. 22 )
14.4 Procedure Modification— If If more detailed infor information mation is available on backload or shock characteristics it is recommended men ded that the above procedur proceduree be mod modified ified to use such information.
13.2 Use the following following test levels: D999,, Method A1 or A2. Test Method —D999 Conditioning—See Section 6. Speciall Instr Specia Instruction uctionss—Dw —Dwell ell tim timee dis distri tribut buted ed 50 % alo along ng normal vertical shipping axis or with the predetermined bottom orientation (as specified in DC-3 and DC-13) facing down and remai re maini ning ng 50 % ev even enly ly alo along ng all ot othe herr po poss ssib ible le sh ship ippi ping ng orientations Assurance Level I II I II
Velocity mph (± 0.5) (± 0.5) (± 0.5) (± 0.5)
15. Schedule H—Environmental H—Environmental Hazard: Hazard: 15.1 This schedule schedule is intend intended ed to provide for the anticipated anticipated and often rapid changes in ambient conditions associated with the military distribution of material. This schedule determines the susceptibility of the total pack to the effects of moisture, temperature shock, or the combined effects of cyclic exposure. Thee re Th resu sult lt of co cond nditi ition onin ing g ma may y in invo volv lvee th thee ob obse serv rvati ation on/ / measurement of moisture or water within packs, evidence of corrosion on packaged items, or compromise of the enclosure’s structural struct ural integrity such that physical protection can no longer be ensured. Testing shall be in accordance with Test Method D951,, where D951 where spr spray ay int intens ensitie itiess of 4 6 0.5 in. in./h /h (10 (100 0 6 10 mm/h) are used for Assurance Level I and 2 6 0.5 in./h (50 6 10 mm/h) for Level II. Water spray temperature is as listed in the table below. During spray segments the air temperature is uncontrolled uncon trolled at ambien ambientt condi conditions. tions.
Dwell Time, min 60 40 30
14. Schedule G—Simulated G—Simulated Rail Switching: 14.1 The test levels and test methods 14.1 methods for this sch schedu edule le are inten in tende ded d to de dete term rmin inee th thee ab abili ility ty of th thee sh ship ippi ping ng un unit it to withstand the acceleration levels and compressive forces that might occur during rail switching operations. Test Method D4003 Method D4003,, Test Method A or Test Method D5277 D5277.. Conditioning—See Section 6. Special Instructions—Four impacts shall be performed. For railcars with standard draft gear, shock durations of 40 6 10 ms shall be used, as measured on the floor of the carriage. For railcars with long–travel draft gear, shock durations of 300 6 50 ms sh shall all be us used ed.. Re Refe fere renc ncee As Asso socia ciatio tion n of Am Amer erica ican n Railroads, General Information Bulletin No. 2. Note that Test Method D5277 Method D5277 is is used for standard draft gear only. Refer to Test Methods D4003 Methods D4003 or or D5277 D5277 for for specific instructions on how to instrument and conduct the test.
15.2 Test levels shall be as follows: Assu As sura ranc nce e Le Leve vell Tem empe pera ratu ture re,, °F (° (°C) C) I 160 ± 5 (71 ± 2) 55 ± 5 (13 ± 2) –5 ± 5 (–21 ± 2) 125 ± 5 (52 ± 2) 55 ± 5 (13 ± 2) 32 ± 5 (0 ± 2) 160 ± 5 (71 ± 2) 55 ± 5 (13 ± 2) –65 ± 5 (–54 ± 2) 160 ± 5 (71 ± 2) 55 ± 5 (13 ± 2) –65 ± 5 (–54 ± 2) 40 ± 5 (4 ± 2) 160 ± 5 (71 ± 2)
14.2 Procedure— Load Load shi shippi pping ng uni unitt on car carria riage ge aga agains instt bulkhead. Use a backload equivalent to a minimum of 3 ft linea lin eall (0 (0.9 .9 m) of ca carg rgo. o. Th Thee pa pack ckag agee us used ed as ba back cklo load ad in cont co ntact act wi with th th thee tes testt pa pack ckag agee mu must st be id iden entic tical al to th thee tes testt package.
II
14.3 Test Levels— Allow Allow the carriage to impact a cushioned barrier in accordance with the following table. Assurance Level I shall be used for open-top open-top rail car load tests. Assur Assurance ance Level II sh shal alll be us used ed fo forr bo boxc xcar ar lo load ad te tests sts fo forr no nonn-ha haza zard rdou ouss materials and for TOFC/COFC load tests for non-hazardous mater mat erial ials. s. Th Ther eree is no As Assu sura ranc ncee Le Leve vell II IIII fo forr th this is Tes estt Schedule. 14.3.1 14. 3.1 If kno known, wn, con contain tainer er imp impact act sur surfac faces es sho should uld be the same as occur in actual shipment. If the shipping orientation is not known, or if more than one orientation is possible, the first three impacts should be on that test specimen surface which is
I II
Wat ater er Sp Spra ray y X X X
X
X
Dura Du rati tion on,, h 16 2 2 2 2 16 4 2 2 16 2 2 3 16
160 ± 5 (71 ± 2) 14 55 ± 5 (13 ± 2) X 2 160 ± 5 (71 ± 2) 4 32 ± 5 (0 ± 2) 2 55 ± 5 (13 ± 2) X 2 The cyclic sequence shall be repeated on three consecutive days. At the end of the three day period, the unit pack being tested shall then set overnight 160 ± 5 (71 ± 2) 16 Not applicable
15.3 Duration time shall be be measured starting the moment at which temperature setting is changed to next condition. 15.4 Wh 15.4 When en sp speci ecifie fied d in th thee co cont ntra ract, ct, th this is te test st sh shou ould ld be performed as part of the complete distribution cycle for the smallest complete shipping unit, as part of the contract. 10
D4169 − 16 16. Schedule I—Low Pressure Pressure (High Altitude) Hazard
18. Repo Report rt
16.1 This schedule schedule is intended to provide for the anticipated anticipated reduction in pressure when packaged products are transported via certain modes of transport, such as feeder aircraft or by ground over mountain passes. This test shall be conducted in accordance with levels described in Test Method D6653 D6653.. This test should be included for products and packages that could be sensitive to a low pressure environment, for example, sealed flexibl flex iblee non non-po -porou rouss pac packag kages, es, liq liquid uid con contain tainers ers,, or por porous ous pack pa ckag ages es th that at ma may y be pa pack cked ed in su such ch a ma mann nner er as to be adversely affected by low pressure environments. This test may be deleted from DC 12 and 13 when shipping units contain primary primar y packag packages es that have a poro porous us material (poro (porous us packaging material is defined in Terminology F1327 Terminology F1327). ).
18.1 Rep 18.1 Report ort fully all the steps taken. taken. At a min minimu imum, m, the report should include: 18.1.1 18.1. 1 Referen Reference ce to this practice, practice, 18.1.2 18.1. 2 Descrip Description tion of prod product uct and shipp shipping ing unit, including orientation of the product within the shipping unit, 18.1.3 18.1. 3 Distrib Distribution ution cycle (DC) and test plan, 18.1.4 18.1. 4 Assur Assurance ance levels and rationale, 18.1.5 18.1. 5 Numbe Numberr of sample sampless tested, 18.1.6 18.1. 6 Condit Conditioning ioning used, 18.1.7 18.1. 7 Accepta Acceptance nce criteria, 18.1.8 18.1. 8 Vi Vibratio bration n option used, rando random m or sine, 18.1.9 18. 1.9 Random Random vib vibrati ration on pow power er spe spectra ctrall den density sity plo plot, t, if used, 18.1. 18 .1.10 10 Press Pressure ure lev levels els and du dura ratio tion n fo forr hig high h alt altitu itude de exposure, if used, 18.1.11 18.1. 11 Type of lift truck handling handling tests used, if any any,, 18.1.12 18.1. 12 Variatio ariation n from recommended recommended proced procedures, ures, and 18.1.13 18.1. 13 Condit Condition ion of specimens after test.
16.2 Tes 16.2 Testt th thee pa pack ckag ages es to th thee ex expe pecte cted d al altit titud udee lev level elss encountered during shipment. If these are not known precisely, use levels recommended by Test Method D6653 of pressure equivalent to 4267 m (14 000 ft.) for a period of 60 min. The test duration and pressure levels may be modified based on knowledge of the shipping environment, product value, desired damage level acceptances, or other criteria as described in Test Method D6653 Method D6653..
Governmentt Shipmen Shipments— ts— In 18.2 Governmen I n ad addi diti tion on to 18.1 18.1.2 .2 – 18.1.13,, the complete report includes: 18.1.13 18.2.1 18.2. 1 Party Party,, other than contr contractor actor,, perfo performing rming testing, 18.2.2 18.2. 2 Testing facility used, other than contractor’s, contractor’s, 18.2.3 18.2. 3 Gover Government nment representative representative witnessing testing, and 18.2.4 18.2. 4 When environmental environmental hazard is perfo performed rmed for other than smallest complete shipping unit (see 15.4 15.4)).
17. Schedule J—Concentrated J—Concentrated Impact 17.1 This schedule schedule provides a simulation of anticipated anticipated low levell con leve concen centra trated ted imp impacts acts as rec receive eived d by pac packag kages es dur during ing sorting operations and in transit. The test is only applicable to lightweight singlewall corrugated shipping containers (under 275 Burst or 44 ECT) and plastic film wrapped packages and unitize uni tized d loa loads. ds. Test the app approp ropria riate te pac packag kages es or uni unitt loa loads ds according to Test Method D6344 D6344..
19. Pre Precisi cision on and Bias 19.1 The precision precision and bias of this practi practice ce are dependent dependent on th thos osee of th thee va vari riou ouss te test st me meth thod odss us used ed,, an and d ca cann nnot ot be expressly determined. 20. Keyw Keywords ords 20.1 compr compression ession test; distribution distribution cycle; distrib distribution ution environment; drop test; mechan ronment; mechanical ical handl handling; ing; package; packa packaging; ging; random vibration; shipping container; shipping unit; vacuum; vibration
17.2 The im 17.2 impa pact ct en ener ergy gy fo forr th this is te test st sh shall all be 4. 4.0 0 ft ft-l -lbf bf (5.4 J) as imposed by the cylindrical mass falling a vertical drop distance of 32 in. (0.8 m).
ANNEX (Mandatory Information) A1. DISTRIBUTION CYCLE CYCLE DC-18 FOR NON-COMMERC NON-COMMERCIAL IAL GOVERNMENT GOVERNMENT SHIPMENTS PER MIL-STD-2073–1
A1.1 A1.1 Performanc Performancee Test Test Schedule Sequence SequenceA1.1 1 2 3 4 5 6 7 8
the last man manual ual handling handling sequence sequence is the same as all other impacts. Use the first sequence impact orientations for the third handling handl ing schedule. Test small shipp shipping ing units using the follow follow-ing test levels:
Handling ( (A1.2 A1.2)) Warehouse or Vehicle Stacking (A1.3 A1.3)) Handling ( (A1.2 A1.2)) Low Pressure Hazard (A1.4 A1.4)) Environmental Hazard ( (A1.5 A1.5)) Loose Load Vibration ( (A1.6 A1.6)) Vehicle Vibration ( (A1.7 A1.7)) Handling ( (A1.2 A1.2))
Shipping Weight, lb (kg) 0 to 30 (0 to 13.6) over 30 to 75 (over 13.6 to 34) over 75 to 150 (over 34 to 68)
A1.2 Handling—Manual and Mechanical
Drop Height, in. (mm) Assurance Level I II 30 (762) 24 (610) 24 (610) 18 (457) 18 (457) 15 (381)
A1.2.2 Mechanical Handling:
Manual Hand Handling— ling— This A1.2.1 Manual T his te test st sch sched edul ulee ap appl plies ies to small shipping units. Description of this schedule is in accordance with 10.2.3 with 10.2.3,, except that the height of the last impact of 11
D4169 − 16 A1.2.2.1 For large shipping A1.2.2.1 shipping units, this schedule is intended to provide a number of testing variations describing specific mechanical handling hazards that occur in government distribution for shipping cases, crates, unitized loads, and cylindrical containers. contain ers. Required tests for rectangular shipping shipping units include: tip/tipover; tip/tipover; fork lift truck transport; transport; rotatio rotational nal drop drops, s, both edgewise and corne cornerwise; rwise; and lateral impacts. For Assurance Level I, shipp shipping ing cases and crates and unitize unitized d loads shall also be subjected to sling handling. For cylindrical shipping units, only rotatio rotational nal edgewise drop tests shall apply apply.. Table A1.1 shall A1.1 shall be used as a guide in determining both the required tests and the sequence to be followed. A1.2.2.2 A1.2. 2.2 Specifi Specificc tests requi required: red: (1)) Sh (1 Shipp ipping ing Cas Cases, es, Cra Crates tes,, an and d Uni Unitiz tized ed Loa Loads– ds–T Tip/ —Shipping cases and crates shall be subjected to both Tipover —Shipping tip an and d tip tipov over er tes tests ts fo forr As Assu sura ranc ncee Lev Level el I, fo follo llowi wing ng th thee requirements of Test Method D6179 D6179,, Methods F and G. For unitized loads, only the tip test will be required. The tip test shall be performed for Assurance Level II for all rectangular shipping units. Tip/tipover requirements shall only be required during the first handling sequence of DC-18. The tip test is useful for determining acceptable shipping unit dimension and center of gravity. For tipover, one impact is required on each of two opposite sides, as determ determined ined by the initial side having the lowest height height–to–w –to–width idth ratio. (2) Shipping Cases, Crates, and Unitized Loads—Fork Lift —Pick up, transport transport aro around und test cou course rse as Truck Tran Transport sport —Pick defined in Test Methods D6055 D6055,, Method A, for a total of two cycles (round trips) in the case of Assurance Level I, and one cycle for Assurance Level II. Within the minimum 100 ft (30.5 m) obstacle zone, parallel pairs of 1 by 6 in. (25 by 150 mm) boards, of a length to extend completely across the aisle and spaced 54 in. (1.37 m) apart, are laid flat at intervals of 30, 60, and 90 ft (9.1, 18.3, and 27.4 m). Board angles to the truck’s path shall be 90, 60, and 75 degrees respectively, with the left wheel striking first over the second obstacle (board pairs) and the right wheel first over the third (3) Shipping Cases, Crates, Unitized Loads and Cylindrical Conta Containers iners—Rota —Rotationa tionall Dr Drops ops—F —For or ed edge ge dr drop ops, s, us usee Method A of Test Test Methods Methods D6179 D6179 with with a 6 in. (150 mm) height timber edge support. In the case of rectangular shipping units, drops are made on each opposite edge of the unit’s base, for a total of four impacts. For cylindrical shipping units, drops shall be made with the unit on its side, such that impacts occur on
top and bot bottom tom rim rimss at dia diagon gonally ally opposite opposite qua quadra drants nts.. Care mustt be tak mus taken en to pre preven ventt the container container from rolling rolling on the support. Additional impacts shall be made in the same manner in different quadrants separated by an approximate 90°, for a total of four drops. For corner drops, use Method B of Test Methods D6179 D6179,, except that one corner of the shipping unit base shall be supported on a 6 in. (150 mm) height block while the other corner on the same end or side rests on a 12 in. (300 mm) height block. Each corner will be impacted, for a total of fourr dro fou drops. ps. Bot Both h edg edgewi ewise se and cornerwis cornerwisee dro drops ps sha shall ll be perfor per formed med on lar large ge rec rectan tangul gular ar shi shippi pping ng uni units. ts. For all rot rotaational tio nal dro drops, ps, test wit with h the lowest drop hei height ght indicated indicated by either gross weight or maximum dimension, using the following test levels. Gross Weight, lb (kg) or Maximum Dimension, Dimens ion, in (mm) over 100 to 250 (45 to 113) or over 60 to 66 (1524 to 1676) over 250 to 500 (to 227) or over 66 to 78 (to 1981) over 500 to 1000 (to 454) or over 78 to 90 (to 2286) over 1000 (over 454) or over 90 (2286)
Drop Height, in. (mm) Assurance Level I II 30 (762) 24 (610) 24 (610)
18 (457)
18 (457)
12 (305)
12 (305)
9 (229)
NOTE—For smaller dimension containers, where it is not possible to reach the desired drop height on corner or edge drops, raise the corner or edge until the container is at its balance point and then release the container to fall on the intended corner or edge.
(4) Shipp Shipping ing Cases, Crates Crates,, and Unitiz Unitized ed Loads Loads–Late –Lateral ral Impacts—Note that this test is to be performed only during the second handling handling sequen sequence ce of Distrib Distribution ution Cycle 18. Testing Testing shall be in accordance with Test Method D880 D880,, Procedure B. Alternatively, testing may be in accordance with Test Method D4003,, Method B, using a short duration programmer, assumD4003 ing the coefficient of restitution is 0.0 and the total velocity change is equivalent to the specified impact velocity. Selection of apparatus, as defined within these test methods, shall also be at the option of the package designer/contractor. As a requirement for Assurance Level I, the impact velocity shall be 7.3 ft/s(2.23 m/s). One lateral impact shall be performed on each side (including ends) surface having a dimension less than 9.5 ft (2.9 m). A4 by 4 in. (100 by 100 mm) timber, placed so as to contact the lower edge of the shipping unit, shall be used as an imp impact actin ing g ha haza zard rd wh when en ev eval alua uatin ting g un uniti itize zed d lo load adss an and d demountable shipping cases.
TABLE A1.1 Mechanical Handling for DC-18, Required Tests and Sequence Assurance LevelA
TipB
TipoverB
Forklift Transport
I II
X X
X -
2 c y c l es 1 c yc le
Unitized Loads
I II
X X
-
2 c y c l es 1 c yc le
X X
Cylindrical
I II
-
-
-
X X
Large Shipping Unit Shipping Cases & Crates
A
Rotational Drops E d ge Corner X X X X
As referenced in 3.2.2, Assurance Levels I and II equate to military levels of protection A and B, respectively. Test to be performed only during the first handling sequence of DC-18. C Test to be performed only during the second handling sequence of DC-18. D Test to be performed only during the third handling sequence of DC-18. B
12
Lateral ImpactsC
Sling HandlingD
X -
X -
X X
X -
X -
-
-
-
D4169 − 16 (5) Shi Shippi pping ng Cas Cases, es, Cra Crates, tes, and Uni Unitize tized d Loa Loads— ds—Sli Sling ng Handling—Test shipping cases, crates, and unitized loads for sling handling, in accordance with Method F of Test Methods D6055,, only D6055 only fo forr As Assu sura ranc ncee Le Leve vell I. No Note te th that at th this is te test st is performed only during the third handling sequence.
(1) For Assurance Levels I and II, the dwell time shall be 2 hours on the base for unitized loads and shipping containers with wi th sk skid id ba base ses, s, an and d 1 ho hour ur in ea each ch of th thre reee mu mutu tual ally ly perpendicular axes for all other shipping containers which may be transported in any orientation. (2) For Assur Assurance ance Level III, dwell time shall be 15 minutes on the shipping container container base plus 7.5 minutes on each of two adjacentt sides. adjacen
A1.3 Warehouse or Vehicle Stacking —Refer to Section 11 11,, Schedule Schedu le B—W B—Wareho arehouse use Stackin Stacking g and Schedu Schedule le C—V C—Vehicle ehicle Stacking.
A1.7 Vehicle Vibration:
A1.4 Low Pressure (High Altitude) Altitude) Hazard:
A1.7.1 A1. 7.1 The tes testt meth method od and levels levels for this sch schedu edule le are intended to determine the ability of shipping units to withstand random vibration during transport. Test Method —Refer —Refer to MIL-STD-810F. Conditioning —See Section 6.
A1.4.1 This schedule A1.4.1 schedule is intend intended ed to provide for the anticipated pa ted re redu ducti ction on in pr pres essu sure re wh when en pa pack ckag aged ed pr prod oduc ucts ts ar aree transported via certain modes of transport, such as by aircraft or by gr grou ound nd ov over er mo moun untai tain n pa pass sses es.. Th This is tes testt sh shou ould ld be included includ ed for prod products ucts and packages that could be sensitive to a low pressure environment, for example, sealed flexible nonporouss packag porou packages, es, liquid containers, containers, or poro porous us packag packages es that may be packed in such a manner as to be adversely affected by low pressure environments.
A1.7.2 Con A1.7.2 Conduc ductt a ran random dom vibratio vibration n test for a tot total al of 9 h using the PSD (power spectral densities) shown below. For the vertical vibration, conduct the test for 3 h on a vertical motion vibration machine. For transverse and longitudinal vibration, conduct the test on a horizontal motion vibration machine for 3 h in each axis.
A1.4.2 A1.4. 2 For pressurized pressurized aircraft transport, transport, test the packages to pressures recommended in Test Method D6653 D6653.. For nonpressu pre ssurize rized d air aircraf craftt tran transpo sport, rt, use 4572 km (15 000 ft) as expected altitude (corresponding pressure in a standard atmosphere: 57.2 kPa or 8.3 psia) and maintain for a period of 60 min.
Vertical Frequency, PSD, Hz g2/Hz 10 0 .0 1 5 0 0 40 0 .0 1 5 0 0 500 0 .0 0 0 1 5 1.04 g rms
A1.5 Enviro Environmenta nmentall Hazard Hazard:: A1.5.1 Ref A1.5.1 Refer er to Sec Section tion 16 16,, Schedule Schedule H—Environmental Hazard. A1.6 Loose Load Vibration Vibration:: A1.6.1 The test levels and the test method for this schedule A1.6.1 of the distribution cycle are intended to determine the ability of the shipping unit to withstand the repetitive shocks occurring during transportation of bulk or loose loads. The test levels and test method account for amplitude, direction, and duration of the repetitive shocks.
Transverse Frequency, PSD, Hz g2/Hz 10 0 .0 0 0 1 3 20 0 .0 0 0 6 5 30 0 .0 0 0 6 5 78 0. 00 0 02 79 0 .0 0 0 1 9 1 20 0. 00 0 19 5 00 0. 00 0 01 0.204 g rms
L o n g i tu d i n a l Frequency, PSD, Hz g2/Hz 10 10 0. 00 6 50 20 20 0. 00 6 50 12 0 0 .0 0 0 2 0 121 0. 00 3 00 2 00 20 0 .0 0 3 0 0 2 40 24 0. 00 1 50 3 40 34 0. 00 0 03 500 0 .0 0 0 1 5 0.740 g rms
A1.7.3 For the vertical motion test, mount mount test specimen to the vibration machine surface in a manner dynamically representative of the life cycle event simulated. For the transverse and longitudinal motion tests, fasten the test specimen to the vibration machine surface by the use of two or more straps over the specimen at right angle to the vibratory motion, tightened down to the machine surface to prevent movement. I-bolts with ratcheting straps are suggested restraining devices.
A1.6.2 A1.6. 2 Use the following test method method and levels: Test Method D999, D999, Method A1 or A2. Conditioning—See Section 6 Section 6.. —Dwell ell time shall be dis distrib tributed uted as fol fol-Speciall Instru Specia Instruction ction—Dw lows:
13
D4169 − 16 APPENDIXES (Nonmandatory Information) X1. EXAM EXAMPLE PLE TEST PLANS PLANS
X1.2.8 Step 8, Perform Tests— Perform Perform tests in accordance with the test plan in Step 5, as direct directed ed in the referenced ASTM standards standa rds and in the special instructions instructions for each test schedule.
X1.1 The following following examples examples will serve to illustrate the use of this practice: X1.2 Exampl —Test est a pac packag kaged ed com commer mercial cial pro produc duct. t. Examplee A—T The moderate value and volume of shipment are typical of other products in the shipper’s line. No damage is acceptable and the package must be in good condition after the test. The fiberboard packaged product weighs 160 lb (73 kg), is 48 in. (1.2 m) long, 20 in. (0.5 m) wide, 24 in. (0.6 m) high, and stacked 2 high on pallets for storage and truckload shipment. The corrugated fiberboard container is 275 psi (1900 kPa) burst grade material. The customer stores palletized loads 2 high on the floor. The product does not support any of the load.
Step 9, Eva Evalua luate te Res Results ults— — Examin X1.2.9 Step Examinee pro produc ducts ts and packages to determine if the acceptance criteria have been met.
X1.2.10 Step 10, Document Test Results— Write Write a report to cover all steps in detail, in accordance with Section 18 18.. X1.3 Example B—Product to be tested is identical to the produc prod uctt fr from om Ex Examp ample le A, ex exce cept pt th that at it wi will ll be sh ship ippe ped d individually through an LTL distribution system, and there is no st stor orag agee of mo more re th than an on onee co cont ntain ainer er hi high gh.. Ad Addi ditio tiona nall information infor mation is that the packag packagee has unsupported unsupported interior spans exceeding 12 in. (0.3 m) on all four sides, and has no pallet or skid.
X1.2.1 Step 1, Define Shipping Unit— Shipping Shipping unit to be tested is a typical pallet load. X1.2.2 Step 2, Establish Assurance Level— Assurance Assurance Level II will be used, based on value and volume of shipment.
X1.3.1 Step 1, Define Shipping Unit— Shipping Shipping unit to be tested is a single package.
Acceptance Criteria at Assurance X1.2.3 Step 3, Determine Acceptance Level II: Criterion 1—No product damage. Criterion 2—All packages in saleable condition.
X1.3.2 Step 2, Establish Assurance Level— Assurance Assurance Level II will be used, based on value and volume of shipment. Acceptance Criteria at Assurance X1.3.3 Step 3, Determine Acceptance Level II: Criterion 1—No product damage. Criterion 2—All packages in saleable condition.
Test Schedules— DC–6 X1.2.4 Step 4, Select Test DC–6 will be used for this palleti palletized, zed, truckl truckload oad shipme shipment. nt.
X1.2.5 Step 5, Write Test Plan: Sequence Test Schedule Test Methods 1 A Handling— D6055 Met Method hod A Mechanical D880 Proced Procedure ure B D6179 Met Method hod C
L ev e l Pick up, Pick up, tra transp nsport ort aro around und tes testt course, set down, 5 cycles. Horizontal Horizo ntal impact all four sides, 4.0 ft/s (1.22 m/s) Rotati Rot ationa onall dro drop, p, one imp impact act on two opposite base edges from 6 in. (0.152 m).
2
D S ta c k e d Vibration
D4728
“Truck” PSD profile “Truck” profile,, 0.52 g rms, duration 180 min, with load stacked on top.A
3
A Handling— Mechanical
D6055 Met Method hod A
Pick up, Pick up, tra transp nsport ort aro around und tes testt course, set down, 5 cycles. Horizontal Horizo ntal impact all four sides, 4.0 ft/s (1.22 m/s) Rotati Rot ationa onall dro drop, p, one imp impact act on two opposite base edges from 6 in. (0.152 m).
D880 Proced Procedure ure B D6179 Met Method hod C
4
B Warehouse Stacking
D642
X1.3.4 Step 4, Select Test Schedules— DC-3 DC-3 will be used for this single package shipment via LTL motor freight. X1.3.5 Step 5, Write Test Plan: Sequence Test Schedule Test Method 1 A Handling— D5276 Manual
Compression of pallet Compression palletload load to 2880 lbf (12 800 N) on F=4.5.
A
Alternative vibration test configurations, 1: test 2 full pallet loads high, or use a dead weight load to simulate the upper pallet load, 2: test a single individual container with 480 lb dead weight load to simulate the load stacked on top of bottom container.
X1.2.6 Step 6, Select Samples for Test— Select Select repre representasentative samples. X1.2.7 Step 7, Condition Samples— Condi Condition tion to 23 6 1°C, 50 6 2 % rel relativ ativee hum humidi idity ty,, in acco accorda rdance nce wit with h Pra Practic cticee D4332.. D4332
L ev e l One drop on top, two drops on adjacent bottom edges, two drops on diagonally opposite bottom corners, one drop on bottom, drop height 7in. (178 mm).
2
D S t ac k ed Vibration
D4728
Truck PSD profile Truck profile,, 0.52 g rms, 60 min on each of two adjacent sides and bottom with concentrated dead load on top, load weighing amount as calculated per D4169, 12.2
3
F L oo oose Lo ad ad Vibration
D999, D999, Method A1 or A2
20 min on bottom, 10 min on each of two adjacent sides.
4
A Handling— Manual
D5276
One drop on vertic vertical al edge, two drops on adjacent side faces, one drop on top corner, one drop on adjacent top edge, drop height 7 in. (178 mm). One drop on bottom, drop height 14 in. (355 mm).
X1.3.6 Step 6, Select Samples for Test— Select Select repre representasentative samples. 14
D4169 − 16 X1.3.7 Step 7, Condition Samples— Condi Condition tion to 23 6 1°C, 50 6 2 % rel relativ ativee hum humidi idity ty,, in acco accorda rdance nce wit with h Pra Practic cticee D4332.. D4332
Step 9, Eva Evalua luate te Res Results ults— — Examin X1.3.9 Step Examinee pro produc ducts ts and packages to determine if the acceptance criteria have been met.
X1.3.10 Step 10, Document Test Results— Write Write a report to cover all steps in detail, in accordance with Section 18 18..
X1.3.8 Step 8, Perform Tests— Perform Perform tests in accordance with the test plan in Step 5, as directed in the referenced referenced ASTM standards standa rds and in the special instructions instructions for each test schedule.
X2. USING THE DC-2 DISTRIBUTION DISTRIBUTION CYCLE
X2.1 X2. 1 The DC-2 distribut distribution ion cycle is use used d whe when n an anticipated distribution is well understood and other cycles, DC-3 through throu gh DC-18 DC-18,, are not suf suffficiently descriptive. descriptive. The under under-standin stan ding g of dis distri tribut bution ion may be dev develop eloped ed in sev severa erall way ways, s, including: measurement of the environment with appropriate instru ins trumen mentati tation; on; car carefu efull obs observ ervatio ation n of the var variou iouss haz hazard ard elements in distribution; reference to published authoritative information; product damage reports; or a combination thereof. X2.2 X2. 2 The user of DC-2 is allo allowed wed complete complete flexibility flexibility in developing a test plan that accurately reflects the anticipated distribution. This includes the ability to vary Assurance Levels between test schedules for each hazard element, as presently stated in 8.2 for app applica lication tion to any Dis Distri tribut bution ion Cyc Cycle. le. The abili ab ility ty to mo modi dify fy tes testt le leve vels ls or ot othe herr de detai tails ls wi with thin in a tes testt schedule is also permitted in DC-2 when experience has shown it more accurately correlates with actual experience.
1
S c he d ul e
m od i fi ed A-handling by the manufacturer
Test Method
Pick up, transp transport ort around test course course,, set down 3 times
D880 Procedure B
Incline impact on each end of the palletized load at 4 ft/s
2
D-transport stacked vibration
D4728 Method A
Truck PSD profile, 0.52 g rms, duration 3 h, two loads high
3
m o di fi e d A-handling by customer
D6055 Method A
Pick up, transp transport ort around test course course,, set down 5 times
D880 Procedure B
Incline impact on each end of the palletized load at 4 ft/s Rotational drop, impact on other end base edge from 6 in.
(2) Comparing this test plan to X1.2, Example A, where DC-6 DC -6 wa wass us used ed,, th thee nu numb mber er of te test stss and and in inte tens nsit itie iess ar aree somewhat somew hat less.
X2.2.1.2 Example 2—Following reports of an unacceptable amount of corner damage in shipments of a consumer product direct from the manufacturer to the consumer via small parcel carriers, a thorough study of handling and transport has been made. Subsequent corner drop tests revealed that a drop of 42 in. high is needed to produce the type of damage reported and inst in stru rume ment nted ed sh ship ipme ment ntss ha have ve ve veri rifie fied d so some me dr drop opss at th that at heig he ight ht.. Th Thee pa pack ckag aged ed pr prod oduc uctt we weig ighs hs 43 lb lb,, an and d ou outsi tside de dimensions of the container are 24 in. length by 10 in. width by 42 in. depth (end-opening 32 ECT grade box). The container and int interio eriorr cor corrug rugated ated pac packag kaging ing pie pieces ces pro provid videe all of the support in compression, and the container is marked with “ This Way Up” arrows in normal depth direction. There is no reported repor ted damage to the corrugated corrugated contain containers ers due to excessive compressive compr essive loads, and instru instrumented mented shipments shipments verif verify y that the container is almost always in a normal depth orientation (42 in. dimension dimens ion upright) during transportation. transportation. The user of DC-2 develops a test plan that simulates the anticipated distribution, as follows:
Details of Test and Levels
D6055 Method A
Rotational drop, imipact one end base edge from 6 in.
D6179 Method C
X2.2.1 The following hypothetical X2.2.1 hypothetical examples illustrate instances where such flexibility is useful. X2.2.1.1 Example 1—For truckload shipments of palletized loads stacked two-high on trailers from a manufacturer to a customer, a thorough study of handling at both ends of the shippi shi pping ng cyc cycle le (ma (manuf nufactu acturer rer and cus custom tomer) er) has sho shown wn the following: no significant impacts against the sides of the loads, only against the ends; seldom any more than one rotational drop of the load on a base edge; small amount of lift truck handling by the manufacturer but a moderate amount by the customer; and no warehousing/stacking of loads in storage by either manufacturer or customer. (1) The user of DC-2 develops a test plan that includes a modified modifie d Sched Schedule ule A Mechanical Handling at the begin beginning ning and at the end of the distribution cycle but does not include a compression test, as follows: S e qu en c e
D6179 Method C
15
D4169 − 16 S eq u en c e
S c h ed u l e
Test Method
Details of Test and Levels
1
modi fi ed A-handling by shippe shipperr and carrier
D5276
Drop test from 21 in. high in six orientations as described in table of 10.2.3 First Sequence of Distri Distribubution Cycles
2
C-stacking in truck
D642
Compression test to 642 lb (M=10.0 lb/ft3, H=108 in., F=7.0
3
F-loose load vibration
D999 A2
4 0 m i n o n b o tto m
4
E-truck vibration
D4728
180 min on bottom bottom,, 0.52 g rms
5
m o d i fi ed A-handling by carrie carrierr and receiver
D5276
Drop test from 21 in high in five orientations as described in table of 10.2.3 Second Sequence of Distribution Cycles. Drop once from 42 in. high on the most damage-prone corner.
(1) Comparing to X1.3 Example B where DC-3 was used, this test plan’s Assur Assurance ance Levels vary between test schedules schedules in the sequence, drop test heights are higher than any listed in the table of 10.2.3 for the shipping weight involved, compression strength streng th is check checked ed for full trailer height of 108 in. (rather than 54 in. height), and vibration tests are conducted in only one orientation rather than three.
REFERENCES (1) Ostrem, Ostrem, F. E., and Lib Libovi ovicz, cz, B. A., “A Survey Survey of Env Enviro ironme nmenta ntall Conditions Condi tions Incident to the Transportation Transportation of Materi Materials,” als,” General American Research Division, October 1971, pp. 204–442. (2) Henz Henzi, i, A. N. N.,, “A Su Surv rvey ey of Tes estt Me Meth thod odss Cu Curr rren ently tly Us Used ed fo forr Simulating the Transportation Environment,” General American Research Division, April 1971, pp.202–728, Prepared for Department of Transportation, Office of Hazardous Materials. (3) Ostrem, F. E., and Rumerman, M. L., “Shock and Vibration TransGeneral Ameri American can Resear Research ch portation porta tion Desig Design n Criter Criteria ia Manua Manual,” l,” General Division, Se Sept ptem embe berr 19 1965 65.. N 66 34 3468 681. 1. Pr Prep epar ared ed fo forr Na Natio tiona nall Aeronautics and Space Administration. (4) Int Intern ernatio ational nal Saf Safee Tr Trans ansit it Ass Associ ociatio ation, n, “Pr “Presh eshipm ipment ent Test Procedures Proce dures,” ,” Proce Procedure dure 1 and 1A, April 1996. (5) EIA Standard RS–414–A, “Simulated Shipping Tests for Consumer Electronic Products and Electronic Components.” Electronic Industries Assoc., February 1975. (6) Preshipm Preshipment ent Te Test st Standa Standard rd for Packa Packaged ged Major Appliances, Appliances, ANSI/ AHAM MA–1–PS–1980. (7) Federal Test Method Standard No. 101C. Preservation, Packaging, and Packaging Materials: Test Procedures, March 1980. (8) “The “The Rai Railro lroad ad Env Enviro ironme nment, nt, A Gui Guide de for Shi Shippe pperr and Rai Railro lroad ad Personnel,” New York Central Railroad Co. , 1966. (9) Packaging for Parcel Post , U.S. Postal Service, November 1974. (10) Ostrem, F. F. E., and Godshall, W. W. D., “An Assessment of the Common Carrier Shipping Environment,” General Technical Report FPL 22, U.S. Forest Product Laboratory, 1979 . Department of (11) “Transpo “Transportabili rtability ty Criter Criteria, ia, Shock and Vibrati ibration,” on,” Department Army Technical Bulletin TB 55–100 Hq., Department of Army, April 1964. (12) Environmental Test Methods, Military Standard 810C, Department of Defense, March 1975. (13) National Motor Freight Classification Item 180, Performance Testing of Shipping Containers, American Trucking Association, Inc., 2011.
(14) Singh, S. P., Saha, K., Singh, J. and Sandhu, A. P. S., “Measurement and Analysis of Vibration and Temperature Levels in Global Intermodal Container Shipments on Truck, Rail and Ship,” Journal of Packaging Technology & Science, Accepted for publication. (15) Singh, S. P., Joneson, E., Singh, J., Grewal, G., “Dynamic Analysis of LessLess-Than-T Than-Trucklo ruckload ad Shipm Shipments ents and Test Metho Method d to Simu Simulate late This Environment,” Journal of Packaging Technology and Science Special Issue: Environmental Data Recording, Analysis and Simulation of Tr Transpo ansport rt Vi Vibrati brations ons, Vol ol.. 21 21,, Is Issu suee 8, pp. 45 453 3 – 46 466, 6, December 2008. (16) Singh Singh,, S. P., Sin Singh, gh, J., Gau Gaur, r, P., Sah Saha, a, K. K.,, “Me “Measu asurem rement ent and Analysis of Vibration Levels on Warehouse and Retail Store Material Handling Equipment,” Journal of Applied Packaging Research , Vol. 2, No. 2, December 2007. (17) Singh, J., Singh, P., P., Joneson, E., “Measurement and Analysis of U.S. Truck Tr uck Vibr ibratio ation n for Leaf Spr Spring ing and Air Rid Ridee Sus Suspen pensio sions ns and Journal of Developmen Devel opmentt of Tests to Simul Simulate ate these Conditions,” Conditions,” Journal Packaging Technology and Science, Vol. 19, Issue 6, pp. 309 – 323, November/December 2006. (18) Frank, B., M. Gilgenbach, and M. Maltenfort, “Compression Testing Packaging Techn echnology ology and to Simu Simulate late realreal-W World Stre Stresses sses,” ,” Packaging Science, 23: 275-282, June, 2010. (19) Singh, J., Singh, S. P. and Saha, K., “Effect of Horizontal Offset on Vertica erticall Compr Compressio ession n Streng Strength th of Stacke Stacked d Corru Corrugated gated Fiberb Fiberboard oard Boxes,” Journal of Applied Packaging Research, Vol. 5, No. 3, pp. 131-144, July 2011. (20) Ievans, Ievans, U., “The Ef Effect fect of Wareho arehouse use Mishandling Mishandling and Stack Stacking ing Patterns on the Compression Strength of Corrugated Boxes,” TAPPI Journal, August, 1975. (21) Singh, S. P., Singh, J. and Saha, K., “Effect of Palletized Box Offset on Compression Strength of Unitized and Stacked Empty Corrugated Fiberboard Boxes,” Journal of Applied Packaging Research, Vol. 5, No. 3, pp. 157-168, July 2011.
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D4169 − 16 SUMMARY OF CHANGES Committee D10 has identified the location of selected changes to this standard since the last issue (D4169–14) that may impact the use of this standard. (Approved April 1, 2016.) (1) Revised 12.1 Revised 12.1,, 12.3 12.3,, 12.4 12.4,, and 12.4.1 and 12.4.1.. (2) Added 12.4.1.1, 12.4.1.1 , 12.4.1.2, 12.4.1.2 , 12.4.1.3, 12.4.1.3 , 12.4.1.4, 12.4.1.4 , 12.4.2, 12.4.2, 12.4.2.1,, 12.4.2.1 12.4.2.1 12.4.2.1(1), (1), 12.4.2.1 12.4.2.1(2), (2), 12.4.2.1 12.4.2.1((3), and 12.4.2.2 and 12.4.2.2..
(3) Added Added Table Table 2, 2, Table 3, 3, and Table and Table 4. 4. (4) Added Added Note Note 4. 4.
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