HLCL Container Inspection Manual

Hapag-Lloyd Container Linie Container Inspection Manual

Version 1.0

Container Inspection Manual

Scope This Manual is based on the “ Hapag-Lloyd Repair and Inspection Guidelines ” as well as additional Instructions generated from know-how and experience during the past decades of Container operation. The purpose of this Manual is to assist Hapag-Lloyd M&R Inspectors to evaluate which damages to a Container under Hapag-Lloyd’s custody require repair and which damages damages are to be considered “acceptable” and as such does NOT require repair. Furthermore the manual will recommend recommend repair methods for individual damages indicated. However, it is not possible to describe every kind of damage/repair in this guideline. As such the local Inspector is invoked invoked to be able to make a decision based on on COMMON SENSE. In case of doubt, please contact contact Hapag-Lloyd Container Engineering Engineering Department Department (2812) for assistance.


Introduction GENERAL 

Items not specifically detailed in this Manual are covered by this general introduction only if they require repair;

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The tolerances / permitted damages listed are not the minimum necessary to meet basic requirements but are selected to ensure the container is serviceable while minimizing the need for repair and thereby preserving asset life;

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The repair method selected should be the most economical and suit the particular repair location


Introduction ACCEPTABLE DAMAGE This is defined as damage that is not to be repaired and includes: 

All flange damages, unless the structural integrity of the container is compromised;

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Deformation of structural members up to ISO +10mm on the side face and ISO +5mm on the end face;

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Previous repairs should not be reworked unless the structural integrity of the container is compromised or it is unsuitable for cargo.


Introduction NON-ACCEPTABLE DAMAGE This is defined as damage that must be repaired because: 

The International Convention for Safe Containers, 1972, as amended (CSC) is violated and container safety is affected:

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The Customs Convention is violated;

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There is a reduction in the internal height dimension by more than 70mm and/or the internal width/length dimension by more than 50mm;

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The container is unsuitable for cargo;

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Cracks in welds are present unless otherwise stated;

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Corrosion which causes loss of structural integrity


Introduction WEAR & TEAR This is defined as unavoidable change or deterioration of the condition of the container brought about by routine operational use and includes: 

Corrosion;

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General paint deterioration;

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Deterioration of door gaskets and fittings;

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Deterioration of door fixings arising from deterioration of doors;

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Floor de-lamination resulting from routine cargo loading and unloading cycles


Introduction MANUFACTURING DEFECTS Manufacturing defects or suspected manufacturing defects are to be reported to Hapag Lloyd Container Engineering Department (2812).


Bottom side rails Holed, cut, torn, broken, cracked, deformation exceeding 50mm.

Weld or straighten, or straighten and weld, or insert, or section, or renew.

Flange dented, cracked, or cut, NOT going into radius or No action required. being in the weld joint to corner post or corner casting. Flange, cracked, or cut, or broken in the weld joint to corner casting, or going into web radius.

Bottom side rail dented less than 50 mm, No action required!

Straighten and weld, or insert.

Bottom side rail improper repaired (weld seam broken). Rework or insert required!


Bottom side rails Example of Hapag-Lloyd Bottom side rail reinforcement with notched lower bottom side rail and cross member flanges


Front and Rear sill Holed, cut, torn, broken, cracked, deformation exceeding 50mm.


Flange dented, cracked, or cut, NOT going into radius or No action required. being in the weld joint to corner post or corner casting. Flange, cracked, or cut, or broken in the weld joint to corner casting, or going into web radius.

Front sill dented if less than 50 mm. No action required!

Straighten and weld, or insert.

Rear sill dented (and cut) more than 50 mm. Repair by inserting recommended!


Cross member Web holed, cut, torn, broken, cracked


Web deformed in excess of 75mm

Straighten, or renew.

Web upper flange separated from floor by more than 10mm

Straighten and fasten, or renew.

Bowed up by more than 50mm

Straighten, or renew.

Cross member flange and web cut. Replacement required!

Cross member web deformed < 75mm. Replacement is required!


Fork lift pocket & gooseneck tunnel assembly Top plate separation from floor in excess of 10mm or floor screws ineffective

Weld or straighten, or straighten and weld, or insert, or renew.

Web holed, cut torn, or cracked in excess of 500mm or extending into a weld connection

Weld, or straighten and weld, or insert, or renew

Lower flange connection to bottom side rail, holed, cut, torn, cracked extending into web radius

Weld, or straighten and weld, or insert, or section, or renew

Top plate pushed up in excess of 50mm, cut torn or broken

Straighten or weld, or straighten and weld, or insert, or renew

Strap broken, cracked, cut, torn, missing

Weld, or straighten and weld, or replace

> 500 mm

Fork lift pocket pocket web cut less less than 500 500 mm. No action required!

Fork lift pocket strap missing. Replacement required!


Floor planks and panels Goug Gouge e grea greate terr than than 15mm 15mm deep deep irre irresp spec ecti tive ve of leng length th

Sect Sectio ion n or rene renew w

Gouge more than 6mm deep and greater than 150mm wide irrespective of length

Section or renew

De-lam De-lamina inatio tion n or other other damage damage (affe (affecti cting ng floor floor strengt strength) h)

Replac Replace, e, if struct structura urall integr integrity ity is compr compromi omised sed

Difference in height between adjacent planks/panels greater than 10mm

Refasten

Floor plate broken. Replacement required!

Floor de-laminated. Replacement required!


Floor fastenings Protruding

Refasten

Three Three or more more adjace adjacent nt broken/ broken/loo loose, se, missin missing g fast fastene eners rs

Refast Refasten en or repl replace ace

Protruding Floor screw. Refasten is required!

More than three adjacent screws broken off. Replacement is required (also the cross member needs to be replaced)!


Top side rails Holed, cut, torn, broken, cracked, deformation exceeding 30mm.

Top side rail dented in excess of 30 mm. Repair by sectioning the damaged part is required!


Top side rail dented less than 30 mm. No action required!


Front and Rear headers Holed, cut, torn, broken, cracked, deformation exceeding 40mm.

Rear header dented less than 40 mm. Repair only when interfering with door operation or broken!


Front header dented in excess of 40 mm. Replacement required!


Front and Rear headers Holed, cut, torn, broken, cracked, deformation exceeding 40mm.

Front header flange cut. No action required!


Front header flange cut. No action required!


Corner posts Holed, cut, torn, broken, cracked


Dents exceeding 20mm

Straighten, or insert, or renew.

Bent, bow or deformation, if exceeding outer faces of corner castings by +5mm on end face or +10mm on side face


Corner post dented in excess of 20 mm and out of ISO dimensions. Insert required!

Rear corner post dented in excess of 20 mm and interfering with door operation. Replacement required!


Corner posts Holed, cut, torn, broken, cracked


Dents exceeding 20mm


Bent, bow or deformation, if exceeding outer faces of corner castings by +5mm on end face or +10mm on side face


Corner post dented less than 20 mm and . No action required!

Front corner post dented in excess of 20 mm. Replacement required!


Corner posts Examples of acceptable Corner post Inserts


Corner posts Examples of NOT acceptable Corner post Inserts


Corner castings Cracked, deformed, broken

Replace

Deformation preventing correct twistlock operation

Replace

Corner casting broken. Replacement required!


Side/front/roof panel incl. header plate Dents into cube which reduce the internal width by more than 50mm from the inner corrugation including multiple dents, or 70mm from the floor to the roof inner corrugation

Straighten, or straighten and weld, patch, insert or renew

Holed, torn or cut

Weld, or straighten and weld, patch, insert or replace

Dents exceeding the outer face or corner casting +40mm

Straighten, or straighten and weld, patch, insert or renew

Side panel out of ISO dimensions by more than 40 mm. Repair by straighten required!

Side panel dented in excess of 50 mm into cubic capacity. Repair by straighten required!


Doors Holed, cut, torn, broken, cracked component or weld, or deformation affecting security and operation of doors

Weld or straighten, or straighten and weld, or patch, or insert, or renew

Missing/broken or loose parts which affect door operation or watertightness

Replace or refix

Handle retainer bolt loose. Re- faste fasten n require required! d!

Locking bar guide cut but not affecting door operation. No action required!


Doors Holed, cut, torn, broken, cracked component or weld, or deformation affecting security and operation of doors

Weld or straighten, or straighten and weld, or patch, or insert, or renew

Missing/broken or loose parts which affect door operation or watertightness

Replace or refix

Loose door gasket affecting the watertightness. Re- faste fasten n require required! d!

Door gasket cut and improperly repaired Insert required!


J Bars If interfering with door operation

J Bar affecting door operation. Insert required!

Weld or straighten, or straighten and weld, or insert

J Bar affecting door operation. Insert required!


Door hold backs (Tie backs) Missing

Door hold back missing. Replacement required!

Renew

Door hold back missing. Replacement required!


Data plates Loose or missing plates

Data plate (Timber treatment) missing. Replacement required!

Refasten or replace

Example of an intact Hapag-Lloyd Data plate.


Lashing devices Broken, cracked, missing or non functional

Lashing bar broken. Re-welding required!

Straighten, or weld, or replace

Lashing ring not functional. Repair required!


Surfaces Glue (Sticky)

Clean and/or paint

Odour, infestation, debris, contamination that can be transferred

Clean and/or remove

Vent Vents s bloc blocke ked, d, loose oose,, damag amaged ed and and not not weat weathe hert rtig ight ht

Repa Repair ir// repl replac ace e

Graffiti / foreign markings - offensive/poss offensive/possibly ibly offensive offensive

Repair/remove

Glue and paper rests remaining on inner panel. Removal required!

Rope remaining on Lash ring. Removal required!


ISO decals Missing or illegible

Container number and weight table missing. Renewal required!

Replace

ISO Container Number improperly applied. Remove and replace!


Rain gutters Damage affecting door operation or exceeding outer face of corner casting +10mm

Rain gutter dented, not affecting door operation. No action required!

Straighten or remove

Rain gutter out of ISO, but not exceeding 10 mm. No action required!


Hazardous Label Remaining on panels

Rests of IMDG Label remaining on Panel. Complete removal required!

Remove

IMDG Label remaining on Panel. Removal required!


Roof bows (Open Top Container) Holed, cut, torn, broken, cracked

Weld, straighten and weld or replace

Dents into cube which reduce the internal height by more than 70mm

Straighten or replace

Missing

Replace

Row bows dented in excess of 70 mm and/or holder ho lder broken. Straighten and renewal required!

Several roof bows missing. Complete replacement required!


Tarpaulin (Open Top Container) Cut, holed

Old Tarpaulin patch (not weather w eather tight). Repair required!

Repair or replace

Tarpaulin cut. Repair or replacement required!


Tarpaulin (Open Top Container) Cut, holed

Wrong Tarpaulin not in accordance with Customs Regulations. Replacement required!

Repair or replace

Tarpaulin cut. Repair or replacement required!

HLCL Container Inspection Manual

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