TECHNICAL SPECIFICATION
FOR
20' x 8' x 8'6" ISO 1CC TYPE
STEEL DRY CARGO CONTAINER
WITH
CORTEN STEEL CONSTRUCTION,
CORRUGATED DOOR,
CORRUGATED ROOF,
1 PAIR OF FORKLIFT POCKET,
2 VENTILATORS &
PLYWOOD FLOOR
FOR
Container Lion
SCOPE
This specification covers the design, construction, materials, testing, inspection and
performance requirements for ISO, 1CC type steel dry cargo
CONTENTS
1. GENERAL
2. DIMENSIONS AND RATINGS
3. MATERIAL AND CONSTRUCTION
4. SURFACE PREPARATION AND PROTECTION
APPENDIX
A. MATERIAL LIST OF MAIN STEEL PARTS
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1. GENERAL
1.1 Operational Environment
The container is designed and manufactured for the carriage of general cargo
by marine, road, and rail. It is designed to maintain its structural and
weather tight integrity within a temperature range of -40° Celsius to +80° Celsius.
1.2 Regulations and Standards
The container will conform to and satisfy the following regulations and
standards (each with the latest edition).
1.2.1 ISO/TC-104
All to meet series 1 freight containers set forth.
ISO 830 Freight containers-terminology.
ISO 668 Series 1freight containers-classification, external dimensions and ratings.
ISO 6346 Freight containers-coding, identification and marking.
ISO 1161 Series 1 freight containers-corner fittings-specification.
ISO 1496-1 Series 1 freight containers-specification and testing-
Part 1 : General cargo containers
ISO 3874 Series 1 freight containers handling and securing
ISO 1894 General purpose series 1 freight containers minimum internal dimensions
ISO 1979 Series 1 freight containers classification min. internal dimensions
1.2.2 T.I.R. Requirements and Certifications
The container shall comply with the customs convention of containers, 1972
and all subsequent revisions to date and will be identified with appropriate
approval plates and markings.
1.2.3 Timber Component Treatment and Certification
All exposed timber components are treated with an Australian government
approved insecticide and the container will be such identified with appropriate
immunization plate.
1.2.4 U.I.C. Registration
The container will be registered and comply with the International Union
of Railways (UIC) code 592-1 OR and 592-2 OR.
1.2.5 CSC Requirements
The container will comply with the rules set forth in the International
Convention for Safe Containers and will be so identified with a plate.
1.2.6 Classification Society
The container will be certified by classification society “Germanischer Lloyd” in
design and individually during its production.
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1.4 Handling
The container will be constructed to be handled under the following
conditions without distortion or effect on its structural integrity:
A. Lifting full by its top corner fittings by means of spreaders
B. Lifting full by its bottom corner fittings by means of fitting at a sling angle
of 45°.
C. Lifting full or empty by forklift at its forklift pocket.
1.5 Transportation
The container will be constructed to be suitable for transportation in normal
operating conditions by modes of:
A. Marine - Seven (7) high stacked based on 30,480kg M.G.W. in cell
guides or
- Four (4) high stacked and secured at the corner fittings by
suitable vertical or diagonal lashings on deck
B. Rail - on flat or container car secured at its bottom corner fittings
C. Road - on flat or chassis secured at its bottom corner fittings
2. DIMENSIONS AND RATINGS
2.1 External Dimensions
Length: 6058mm 0 -6
Width: 2438mm 0 -5
Height: 2591mm 0 -5
2.2 Internal Dimensions
Length: 5898mm 0 -6
Width: 2352mm 0 -5
Height: 2395mm 0 -5
2.3 Diagonal Difference
Diagonal tolerance of front and rear frames should be less than 10mm
Diagonal tolerance of side and roof panels should be less than 13mm
2.4 Internal Capacity
33.2 m³. (1,173 ft³.)
2.5 Door Opening
Width: 2340mm 0 -5
Height: 2280mm 0 -5
2.6 Ratings
Max. Gross Wt.: 30,480kg (67,200 LBS)
Max. Payload: 28,295kg (62,380 LBS)
Tare Wt. +/-2%: 2,185kg (4,820 LBS)
2.7 Corner Protrusions
2.7.1 The faces of the bottom corner fittings protrude from lower faces of all
transverse members in the base of the container by 14.5mm (+3-3.5mm).
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2.7.2 The upper faces of top corner fittings protrude from upper faces of the
highest point of the roof by 6mm.
2.7.3 The outer side faces of corner fittings protrude from outside faces of corner
posts by 3mm.
2.7.4 Under 1.8 x max. gross weight no part of the base will protrude more than 6mm
below the bottom corner fittings.
3. MATERIAL AND CONSTRUCTION
3.1 General
The container is mainly constructed with steel frames, corrugated panels
welded by CO2 shielded Arc welding. All welds of the exterior including the
base frames are continuous with full penetration. Wooden floor is fixed to
the cross members by self-tapping screws. All crevices will be sealed with
elastic sealing compound.
3.2 Materials
The main constructional materials are shown in Appendix A of the
specification.
3.3 Corner Fittings
All corner fittings used will comply with ISO/1161 standard.
3.4 Base Structure
3.4.1 The bottom side rails are of 158 x 48 x 30 x 4.5mm thick channel section steels
with a pressed profile as shown in drawing attached.
3.4.2 The cross members consist of 16 pcs of 122 x 45 x 45 x 4mm thick steel channel
and 2 pcs of 122 x 80 x 45 x 4mm thick members at the floor joints.
3.4.3 Each forklift pocket is of 2 pcs of cross members welded with a 3.2mm thick top
plate and 2 bottom end plates 200mm deep x 6mm thick.
3.4.4 Four corner gussets, t4 x 200mm thick protection plates will be welded from
side rail to corner fittings.
3.5 Floor
3.5.1 The floor is of 28mm thick plywood. All joints between each plywood and the
whole floor perimeter are sealed with an elastic sealant.
3.5.2 The plywood used will be 19 plies and will be:
A. Hardwood (Apitong or Keruing) of a specific gravity range of 0.7-0.85
at a moisture content of 12%.
B. Moisture content will be 13-15% when fitted to the container.
3.5.3 The plywood used will be certified to meet the requirements of Australian
Commonwealth Dept. of Health (Plant Quarantine Treatment Schedule) for
Timber Components (T.C.T).
3.5.4 The floor will be fixed to the steel cross members by zinc-plated self-tapping
screws. The head of these screws are countersunk below the level of the
upper surface of the floor by 2mm to 2.5mm. The smaller floorboards are
mounted at the rear side close to the door.
3.5.5 The floor spacer with t4 x 50mm flat bar will run the full length in centre.
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3.6 The Front Frame
3.6.1 The bottom end rail is of 4mm thick pressed steel and formed into open
sections. The bottom end rail has 4 pcs inner vertical gussets.
3.6.2 Each front corner post is a single pressed section of 6mm steel.
3.6.3 The top front rail is a upper plate of 3mm thick and a 60 x 60 x 2.3mm thick
square tube forming its profile.
3.6.4 The front panel is of 2 pcs of corrugated 2mm steel panel.
3.7 The Rear Frame
3.7.1 The door sill (rear bottom rail) is of 4.5mm thick pressed steel and formed
into open sections. Each door sill has 4 pcs inner vertical gussets located
just behind the cams of the door locking assembly.
3.7.2 The rear corner post is a single piece of pressed section of 6mm thick
reinforced on the inside with a 113 x 40 x 10mm channel.
3.7.3 The door header has a 3mm thick top plate with a 4mm "U" channel at the
bottom forming into a box shape.
3.8 Side Walls
3.8.1 The side walls are of 5 pcs of 2mm thick steel panels of both ends and 1.6mm
thick intermediate steel panels without marking panels, vertically trapezium
corrugated steel panels continuously welded to each other and to the end rails
and corner posts. Welding penetration side panels to rails should be min.
75%.
3.8.2 The top side rails are 60 x 60 x 2.3mm steel square tube.
3.9 Roof
3.9.1 The roof is of 5 pcs corrugated 2mm steel panels with a 5mm camber
continuously welded to the upper frame.
3.10 Door
3.10.1The doors are constructed with corrugated steel panels. The panel thickness is
2mm. The top and bottom horizontal door members are of 3.2mm thick
pressed 'U' type members. The vertical door members are of 50 x 100 x 3.2mm
thick rectangle tube.
3.10.2 Each door is capable of swinging 270° when fully opened and can be secured in
that position by means of nylon ropes attached.
3.10.3 The right door is so designed that the right door must be opened before the
left in compliance with T.I.R. requirements.
3.10.4 The door gasket is of extruded EPDM with a double lip to ensure water
tightness. The upper and side gaskets are of 'J' type configuration. Bottom is
of a 'C' type configuration. It is attached with sealant and secured with a
stainless steel retainers by blind rivets.
3.10.5 Each door is suspended by four hinges with stainless steel pins, nylon
bushings and brass washers placed at the hinge pin lugs of the rear corner
posts.
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3.10.6 Galvanized locking devices on a galvanized ø34mm pipe are secured to the
door with nuts and bolts and has nylon bushings on the brackets. The Locking
devices will be installed after the container is painted.
Type: Haihang “E-Type” with forged handle or equivalent.
see attached drawings:
“Exploded View”no. HH—E Type
“F-Handle” no. 97HH—E—05—1
3.10.7 A door holder per door, made of mixed nylon rope, is tied to the center-side
locking rod and the receptacle (hook type) is welded to each bottom side rail to
retain the door at the open position.
3.11. Sealant
Butyl based sealant is to be used for non-exposed parts such as floor lap
joint area and between door gasket and frame. For internal exposed parts
such as the periphery of the floor, chloroprene sealant is to be used.
3.12 Special Features
3.12.1 Shoring Slots: 60 x 40mm slots are provided for on each of the rear corner
posts so that a 2" thick batten can be secured to give protection against
shifting cargo.
3.12.2 Lashing Rings: 4 rings with ø12mm will be welded to each of the bottom
and top side rails. Each lashing point is designed to provide a “2000kg pull
load in any direction” without any permanent deformation of lashing ring and
surrounding area.
2 lashing bars will be welded to each corner post at the position of 150mm
higher from top surface at bottom corner fitting and 150mm lower from the
bottom surface of top corner fitting. Each lashing rod on the corner post is
designed to provide a “1000kg pull load in and direction“ without any
permanent deformation.
3.12.3 Ventilators - ventilators should be small type fabricated from A.B.S. resin by
injection molding process. They will be secured to the second corrugation
recess from right corner post of both side walls, by means of three Aluminum
Huck bolts.
3.12.4 Two pcs of 200 x 75 x 9mm thick cone damage protectors ('C' channels) are
placed at both sides of front end rail as well as door sill.
3.12.5 Reinforcement plates - the 300 x 270 x 4mm steel plate are welded to the upper
surface of the top end frames around the top corner fittings.
3.12.6 Customs Seal Provision
Customs seal provision are made on each locking handle and retainer in
accordance with TIR requirements.
4. SURFACE PROTECTION
4.1. Surface Preparation
All steel components, prior to forming, will be shot-blasted to a SA 2.5 standard
surface by means of an automatic centrifugal shot surface cleaning machine. A
weld-able primer compatible to the paint system will be applied immediately to a
thickness of 10 micron to preserve the surface integrity during the assembly
process. After the container is assembled it is shot-blasted again manually to
clean all the welds and any other area that was contaminated during the
assembly process. Slags and spatters are removed by means of grinding or
needle hammers.
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4.2 Paint
Supplier: Hempel – Hai Hong
Exterior: Color: RAL 5010 Gentian blue
Apply one coat of zinc rich primer no. Hempadur Zinc 15360 to 30 mic. DFT.
Apply one coat of epoxy resin primer no. Hempadur Hi-Build 45200/45201 to 40
mic. DFT. (Grey)
Apply one coat of Acrylic top coat no. Hempatex 56430 to 40 mic. DFT. (50 mic.
DFT. On roof)
Total 110 mic. DFT. (120 mic. DFT. On roof)
Interior: Color: RAL 7035 Light grey
Apply one coat of zinc rich primer no. Hempadur Zinc 15360 to 30 mic. DFT.
Apply one coat of epoxy resin top coat no. Hempadur Hi-Build 45200/45201 to
60 mic. DFT.
Total 90 mic. DFT.
4.3. Undercoating
The whole underside will be coated with 35 mic. of zinc rich primer no.
Hempadur Zinc 15360 and 200 mic. of Waxy or Bituminous undercoating.
Color: Black
Total 235 mic. DFT.
Issued in June 2010, subject to modifications and ammendments.
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APPENDIX A
Material list for main steel parts:
YP = YIELD POINT (kg/mm²)
E = ELONGATION %
TS = TENSILE STRENGTH (kg/mm²)
FRONT PANEL - SPA-H OR EQUIVALENT
FRONT TOP RAIL - YP=35 TS=49 E=22
FRONT CORNER POST -
FRONT BOTTOM RAIL -
REAR CORNER POST-OUTER -
DOOR PANEL -
DOOR HEADER -
DOOR RAIL -
DOOR EDGE MEMBER -
DOOR SILL -
SIDE PANEL -
TOP SIDE RAIL -
BOTTOM SIDE RAIL -
ROOF PANEL -
CROSS MEMBER -
REINFORCEMENT PLATE -
FORK LIFT POCKET -
FLOOR SPACER -
DOOR SEAL RETAINER - STAINLESS
CONE DAMAGE PROTECTOR - JIS: SS41 HOT ROLLED
SHAPED STEEL
YP=25 TS=41 E=21
REAR CORNER POST-INNER - JIS: SM50YA HOT-ROLLED
HI-TENSILE SHAPED STEEL
YP=37 TS=50 E=15
LOCKING BAR - JIS: STK41
YP=23 TS=41 E=23
CORNER FITTING - JIS: SCW49 MOD. WELDABLE
CASTING
YP=28 TS=49 E=20
DOOR HINGE - JIS: S25C FORGING STEEL
YP=23 TS=44 E=20
DOOR LOCKING CAM - JIS: S20C FORGING STEEL
AND KEEPER - YP=23 TS=44 E=19
