Repair manual for steel dry containers/Инструкция по ремонту стальных сухих контейнеров

Издание на английском языке
This publication is a practical guide to the inspection and repair of steel dry cargo containers. It covers the purpose and structure of repair manuals, general quality requirements, economic criteria, materials used, welding, painting, and marking. It describes in detail the design of 20- and 40-foot containers, including their main components and elements: frame, doors, front and rear walls, side panels, roof, floor, corner posts, and fittings. Special attention is paid to Maersk inspection criteria, the distinction between acceptable and unacceptable damage, manufacturing defects, and the selection of repair methods. The publication includes decision-making diagrams, methods for straightening, welding, insertion, part replacement, surface preparation, and painting, as well as reference photographs for practical use.

Contents
1. Scope
1.1. The purpose of this manual
1.2. Repair methods
1.3. Structure of the manual
1.4. How to use the manual
1.5. How to update the manual
1.6. In case of doubt
1.7. Updating of repair manuals
2. General requirements
2.1. Quality standards
2.2. Economic criteria
2.3. Standard time system (STS)
3. Materials
3.1. General
3.2. Steel
3.3. Fasteners
3.4. Ventilators
3.5. Floorboards
3.5.1. Plywood Floors
3.5.2. Bamboo Floors
3.5.3. WPC Floors
3.5.4. Others
3.6. Sealant
3.7. Door gaskets
3.8. Solvent
3.9. Welding
3.10. Painting
3.11. Marking
4. General structure of steel containers
4.1. 20ft steel dry container
4.2. 40ft steel dry container
4.3. 20ft base assembly
4.4. 40ft base assembly
4.5. Rear assembly
4.6. Door assembly
4.7. Front assembly
4.8. Side wall assembly
4.9. Roof assembly
5. Maersk container inspection criteria (MCIC)
5.1. Wear and tear
5.2. Acceptable damage
5.3. Unacceptable damage
5.4. Manufacturing defects
5.5. Defects glossary of terms
5.6. Inspection and repair method
5.6.1. Rails, Headers and Sills
5.6.2. Posts
5.6.3. Under-Structure
5.6.4. Floor
5.6.5. Doors
5.6.6. Panels
5.6.7. Others
5.6.8. Cleanliness
6. Decision diagram & repair methods
6.1. Top side rail (TSR)
6.1.1. Decision Diagram for TSR Repair
6.1.2. Straightening
6.1.3. Straightening and Welding
6.1.4. Inserting
6.1.5. Sectioning
6.1.6. Sectioning, Extending to Corner Casting
6.1.7. Guiding Photos
6.2. Bottom side rail (BSR)
6.2.1. Decision Diagram for BSR
6.2.2. Straightening
6.2.3. Straightening and Welding
6.2.4. Inserting
6.2.5. Sectioning
6.2.6. Guiding Photos
6.3. Front header
6.3.1. Decision Diagram for Front Header
6.3.2. Straightening
6.3.3. Straightening & Re-Welding
6.3.4. Inserting
6.3.5. Repair of Corner Protection Plate (Roof Gusset)
6.3.6. Replacement of Front Header and Roof Gusset
6.3.7. Guiding Photos
6.4. Rear (door) header
6.4.1. Decision Diagram for Door Header
6.4.2. Straightening
6.4.3. Straightening and Re-Welding
6.4.4. Inserting
6.4.5. Repair of Corner Protection Plate (Roof Gusset)
6.4.6. Replacement of Rear Header & Corner Protection Plate
6.4.7. Replacement of Cam Keepers
6.4.8. Guiding Photos
6.5. Front sill
6.5.1. Decision Diagram for Front Sill
6.5.2. Straightening
6.5.3. Straightening and Re-Welding
6.5.4. Inserting
6.5.5. Extension to Corner Casting or Channel Repair
6.5.6. Guiding Photos
6.6. Rear sill
6.6.1. Decision Diagram for Rear Sill
6.6.2. Straightening
6.6.3. Straightening and Re-Welding
6.6.4. Inserting
6.6.5. Extension to Corner Casting or Channel Repair
6.6.6. Replacement of Rear Sill
6.6.7. Guiding Photos
6.7. Front corner post
6.7.1. Decision Diagram for Front Corner Post
6.7.2. Straightening
6.7.3. Inserting
6.7.4. Replacement of the Entire Corner Post
6.7.5. Guiding Photos
6.8. Rear corner post
6.8.1. Decision Diagram for Rear Corner Post
6.8.2. Straightening
6.8.3. Inserting
6.8.4. Replacement of the Entire Post
6.8.5. Guiding Photos
6.9. Corner fitting (casting)
6.9.1. Decision Diagram for Corner Casting
6.9.2. Replacement
6.10. Forklift pocket
6.10.1. Decision Diagram for Forklift Pocket
6.10.2. Straightening
6.10.3. Inserting
6.10.4. Replacement of FLP Assembly
6.10.5. Guiding Photos
6.11. Gooseneck tunnel (GNT)
6.11.1. Decision Diagram for GNT
6.11.2. Straightening
6.11.3. Inserting
6.11.4. Sectioning
6.11.5. GNT Components and Assembly Replacements
6.11.6. Guiding Photos
6.12. Cross members and outriggers
6.12.1. Decision Diagram for Cross Members & Outriggers
6.12.2. Straightening
6.12.3. Inserting
6.12.4. Replacement
6.12.5. Guiding Photo
6.13. Floorboards
6.13.1. Decision Diagram for Floorboards
6.13.2. Less-than-complete Floor Panel Replacement
6.13.3. Complete Floor Panel Replacement
6.13.4. Guidelines to Floorboard Repair - 2014
6.13.5. Guiding Photos
6.14. Door assembly
6.14.1. Decision Diagram for Door Assembly
6.14.2. Guidelines to Door Locking System Repair - 2014
6.14.3. Straightening and Re-Welding
6.14.4. Inserting or Patching
6.14.5. Replacement of Door Assembly
6.14.6. Door Hardware
6.14.7. Door Gasket
6.14.8. Guiding Photos
6.15. Side panel
6.15.1. Decision Diagram for Side Panel
6.15.2. Straightening
6.15.3. Straightening and Welding
6.15.4. Inserting
6.15.5. Full-Height Side Panel Replacement
6.15.6. Guiding Photos
6.16. Front panel
6.16.1. Decision Diagram for Front Panel
6.16.2. Straightening
6.16.3. Straightening and Re-welding
6.16.4. Inserting
6.16.5. Full-Height Front Panel Replacement
6.16.6. Guiding Photos
6.17. Roof panel
6.17.1. Decision Diagram for Roof Panel
6.17.2. Straightening
6.17.3. Straightening and Re-welding
6.17.4. Inserting or Patching
6.17.5. Full Roof Panel Replacement
6.17.6. Guiding Photos
6.18. Ventilator
6.18.1. Decision Diagram for Ventilator
6.18.2. Ventilator Repairs
6.18.3. Guiding Photos
6.19. Lashing rings & bars
6.19.1. Decision Diagram for Lashing Rings & Bars
6.20. Surface preparation & painting
6.20.1. Decision Diagram for Surface Preparation & Painting
6.20.2. De-greasing
6.20.3. Water Soluble Contaminants
6.20.4. Dust
6.20.5. Welds
6.20.6. Burned and Charred Paint
6.20.7. Edges
6.20.8. Blast Cleaning
6.20.9. Power Tools
6.20.10. Standards
6.20.11. Roughness
6.20.12. Paint
6.21. Marking
6.21.1. Marking Drawings
7. Revision list