Container Inspection Manual

Introduction

GENERAL
 Items not specifically detailed in this Manual are covered by this general introduction
only if they require repair;
 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;
 The repair method selected should be the most economical and suit the
particular repair location

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Container Inspection Manual

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;
 Deformation of structural members up to ISO +10mm on the side face and ISO
+5mm on the end face;
 Previous repairs should not be reworked unless the structural integrity of
the container is compromised or it is unsuitable for cargo.

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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:
 The Customs Convention is violated;
 There is a reduction in the internal height dimension by more than 70mm and/or
the internal width/length dimension by more than 50mm;
 The container is unsuitable for cargo;
 Cracks in welds are present unless otherwise stated;
 Corrosion which causes loss of structural integrity

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Container Inspection Manual

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;
 General paint deterioration;
 Deterioration of door gaskets and fittings;
 Deterioration of door fixings arising from deterioration of doors;
 Floor de-lamination resulting from routine cargo loading and unloading cycles

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Introduction
MANUFACTURING DEFECTS

Manufacturing defects or suspected manufacturing defects are to be reported to

Hapag-Lloyd Container Steering Department (2920).

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Container Inspection Manual

Bottom side rails

Holed, cut, torn, broken, cracked, deformation Weld or straighten, or straighten and weld, or insert, or
exceeding 50mm. 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 Straighten and weld, or insert.
corner casting, or going into web radius.

Bottom side rail dented less than 50 mm, No action required! Bottom side rail improper repaired (weld seam broken). Rework o

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Container Inspection Manual

Bottom side rails

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

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Container Inspection Manual

Front and Rear sill

Holed, cut, torn, broken, cracked, deformation Weld or straighten, or straighten and weld, or insert, or
exceeding 50mm. 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 Straighten and weld, or insert.
corner casting, or going into web radius.

Front sill dented if less than 50 mm. No action required! Rear sill dented (and cut) more than 50 mm. Repair by inserting

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Container Inspection Manual

Cross member
Web holed, cut, torn, broken, cracked Weld or straighten, or straighten and weld, or insert, or
section, or renew.
Web deformed in excess of 75mm Straighten, or renew.
Web upper flange separated from floor by more Straighten and fasten, or renew.
than 10mm
Bowed up by more than 50mm or below line of Straighten, or renew.
corner castings

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

Cross member flange and web cut. Replacement required!

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Fork lift pocket & gooseneck tunnel assembly
Top plate separation from floor in excess of 10mm or
floor screws ineffective
Web holed, cut torn, or cracked in excess of 500mm or
extending into a weld connection
Lower flange connection to bottom side rail, holed, cut,
torn, cracked extending into web radius
Top plate pushed up in excess of 50mm, cut torn or
broken
Strap broken, cracked, cut, torn, missing
< 500 mm
Fork lift pocket web cut less than 500 mm. No action required!
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Weld or straighten, or straighten and weld, or insert, or
renew.
Weld, or straighten and weld, or insert, or renew
Weld, or straighten and weld, or insert, or section, or
renew
Straighten or weld, or straighten and weld, or insert, or
renew
Weld, or straighten and weld, or replace
Fork lift pocket strap missing. Replacement required
Container Inspection Manual

Floor planks and panels

Gouge greater than 15mm deep irrespective of length Section or renew
Gouge more than 6mm deep and greater than 150mm Section or renew
wide irrespective of length
De-lamination or other damage (affecting floor strength) Replace, if structural integrity is compromised
Difference in height between adjacent planks/panels Refasten
greater than 10mm

Floor plate broken. Replacement required!

Floor de-laminated. Replacement required!

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Container Inspection Manual

Steelfloor
Dents into the cube which prevent proper cargo stowage Straighten, or straighten and weld or insert
and/or securing
Downward dents exceeding 25 mm Straighten, or straighten and weld or insert
Holed, torn or cut Weld, or straighten and weld or insert

Repair suggestion

1st install insert at dama

2nd install round steel pie

Broken steelfloor which is requiring repair

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Container Inspection Manual

Floor fastenings
Protruding Refasten
Three or more adjacent broken/loose, missing fasteners Refasten or replace

Protruding Floor screw. Refasten is required!

More than three adjacent screws broken off.

Replacement is required (also the cross member needs to be re

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Container Inspection Manual

Top side rails

Holed, cut, torn, broken, cracked, deformation Weld or straighten, or straighten and weld, or insert, or
exceeding 30mm. section, or renew.

Top side rail dented in excess of 30 mm. Top side rail dented less than 30 mm. No action required!
Repair by sectioning the damaged part is required!

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Container Inspection Manual

Front and Rear headers

Holed, cut, torn, broken, cracked, deformation Weld or straighten, or straighten and weld, or insert, or
exceeding 40mm. section, or renew.

Rear header dented less than 40 mm. Front header dented in excess of 40 mm. Replacement required!
Repair only when interfering with door operation or broken!

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Front and Rear headers

Holed, cut, torn, broken, cracked, deformation Weld or straighten, or straighten and weld, or insert, or
exceeding 40mm. section, or renew.

Front header flange cut. No action required! Front header flange cut. No action required!

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Container Inspection Manual

Corner posts
Holed, cut, torn, broken, cracked Weld or straighten, or straighten and weld, or insert, or
renew.
Dents exceeding 20mm Straighten, or insert, or renew.

Bent, bow or deformation, if exceeding outer faces of Straighten, or insert, or renew.

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.

Rear corner post dented in excess of 20 mm and interfering with
Insert required! Replacement required!

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Container Inspection Manual

Corner posts
Holed, cut, torn, broken, cracked Weld or straighten, or straighten and weld, or insert, or
renew.
Dents exceeding 20mm Straighten, or insert, or renew.

Bent, bow or deformation, if exceeding outer faces of Straighten, or insert, or renew.

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!

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Corner posts

Examples of
acceptable
Corner post Inserts

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Container Inspection Manual

Corner posts

Examples of
NOT acceptable
Corner post Inserts

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Container Inspection Manual

Corner castings
Cracked, deformed, broken Replace
Deformation preventing correct twistlock operation Replace

Corner casting broken. Replacement required!

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Container Inspection Manual

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
Holed, torn or cut
Dents exceeding the outer face or corner casting
+40mm
Straighten, or straighten and weld, patch, insert or
renew
Weld, or straighten and weld, patch, insert or replace
Straighten, or straighten and weld, patch, insert or
renew

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

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

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Container Inspection Manual

Doors
Holed, cut, torn, broken, cracked component or weld, or Weld or straighten, or straighten and weld, or patch, or
deformation affecting security and operation of doors insert, or renew
Missing/broken or loose parts which affect door Replace or refix
operation or watertightness

Handle retainer bolt loose. Re- fasten required! Locking bar guide cut but not affecting door operation. No action

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Container Inspection Manual

Doors
Holed, cut, torn, broken, cracked component or weld, or Weld or straighten, or straighten and weld, or patch, or
deformation affecting security and operation of doors insert, or renew
Missing/broken or loose parts which affect door Replace or refix
operation or watertightness

Door gasket cut and improperly repaired Insert required!

Loose door gasket affecting the watertightness. Re- fasten required!

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Container Inspection Manual

J Bars
If interfering with door operation Weld or straighten, or straighten and weld, or insert

J Bar affecting door operation. Insert required!

J Bar affecting door operation. Insert required!

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Door hold backs (Tie backs)

Missing Renew

Door hold back missing. Replacement required!

Door hold back missing. Replacement required!

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Container Inspection Manual

Data plates
Loose or missing plates Refasten or replace

Data plate (Timber treatment) missing. Replacement required!

Example of an intact Hapag-Lloyd Data plate.

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Container Inspection Manual

Lashing devices
Broken, cracked, missing or non functional Straighten, or weld, or replace

Lashing bar broken. Re-welding required! Lashing ring not functional. Repair required!

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Container Inspection Manual

Surfaces
Glue (Sticky) Clean and/or paint
Odour, infestation, debris, contamination that can be Clean and/or remove
transferred
Vents blocked, loose, damaged and not weathertight Repair/ replace
Graffiti / foreign markings Repair/remove
- offensive/possibly offensive

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

Rope remaining on Lash ring. Removal required!

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Container Inspection Manual

ISO decals
Missing or illegible Replace

Container number and weight table missing. Renewal required! ISO Container Number improperly applied. Remove and replace!

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Container Inspection Manual

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

Rain gutter out of ISO, but not exceeding 10 mm. No action requi
Rain gutter dented, not affecting door operation. No action required!

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Container Inspection Manual

Hazardous Label
Remaining on panels Remove

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

IMDG Label remaining on Panel. Removal required!

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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 Straighten or replace
more than 70mm
Missing Replace

Several roof bows missing. Replacement required!

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

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Container Inspection Manual

Tarpaulin (Open Top Container)

Cut, holed Repair or replace

Old Tarpaulin patch (not weather tight). Repair required! Tarpaulin cut.
Repair or replacement required!

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Container Inspection Manual

Tarpaulin (Open Top Container)

Cut, holed Repair or replace

Wrong Tarpaulin not in accordance with Customs Regulations.

Replacement required! Tarpaulin cut.
Repair or replacement required!

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