Box Bulletin no.

: 00124

To: All Customers and Operators of Reefer Containers

From: MCI Box Service Team

Date: 21st November 2019

Revised: 26th April 2022

Regarding: Rivet repair procedure for delaminated FRP at aluminum foil layer

FRP: Fiberglass-reinforced Plastics Lining (Q-Liner)

Affected Factory: MCIQ: √ MCIS: √

Type: 40’ x 8’x 9’6” reefer containers

Affected Period: MCIQ manufactured containers with Q-Liner (FRP inner lining)

Year 2011 to 2016

MCIS manufactured containers with Q-Liner (FRP inner lining)

Year 2016

Inspection / Repair: To be Continuously: After Repair no Re-inspection required: √

_________________________________

Important Information:

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400

Classification: Internal
 Repair procedure for delaminated FRP at aluminum foil layer by rivets

1. Introduction
2. Safety
3. Tools and equipment
4. Materials
5. Condition of delamination
6. Repair method
7. Delaminated area
8. Turn container
9. Cut the outer layer of FRP material
10. Mold
11. Repair procedure step by step
12. Turn container back to upright condition
13. Small, delaminated area
14. Mold drawings
15. Air leak test

1. Introduction

A number of 40’ reefer containers have been detected in service with delaminated FRP
inner lining at the aluminum foil in the middle layer of FRP.
Delaminated areas can be repaired by either the rivet method or using glue (separate
repair instruction) to bond the multilayer FRP lining.
If roof lining has soft bubbles larger than 150 mm, it is recommended to use the gluing
repair method on roof lining.
Visible soft bubbles are general found on roof lining only, as it’s made of thinner material
than side lining.

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 2 of 17

Classification: Internal
 2. Safety Gear

a. Safety glasses
b. Safety shoes
c. Hearing protection
d. Working gloves
e. Single use protection gloves
f. Dust mask
g. Safety helmet, should be used, when working with the turnbuckle / cargo bars

3. Tools and equipment

a. Angle grinder
b. Cutting discs for the angle grinder (“3.2 mm” Thick disc)
c. Drilling machine
d. 5.0 mm drill
e. Drill stop
f. Tape measure
g. Rivet gun
h. Sealant gun
i. Spatual or a plastic scraper
j. Utility knife
k. Small screwdriver
l. Mold for pressing, drilling and riveting of FRP material, see the bottom of bulletin
m. 2 pieces cargo bars or turnbuckles
n. Work light

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 3 of 17

Classification: Internal
 4. Materials

a. 4.8 mm aluminum rivets, length minimum 12 mm, head size diameter 15 mm.
MCI spare part number for the 4.8 mm aluminum rivet: P/N 7816124

* Rivet mandrel to be stainless steel or aluminum

* Rivet head are recommended to be aluminum type.
* Rivets must be of high swelling type during installation (see above photo)
* Consumption per complete panel, approximate 500 rivets

b. Polypropylene (PP) Primer

c. Sealant: Teroson MS 930 or equivalent sealant
d. Masking tape
e. Soapy water

5. Condition of delamination

Please cut 100 mm on the outer layer of FRP to determine where FRP material are
delaminated. If layers can be easily separated by using sharp object and still good
adhesion to foam is found, then proceed to next section of repair procedure

FRP material is separated in the middle layer. There is an

aluminum foil in between inner and outer layer of FRP.

a) Outer layer is delaminated from aluminum foil.

b) Inner layer is attached to the foam. Check that
inner layer has a good adhesion to foam.
c) If inner layer has good adhesion to foam,
use rivet repair method
d) If FRP has poor adhesion to foam, the rivet
repair method can’t be used.
Glue repair method must be used

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 4 of 17

Classification: Internal
 6. Repair Method: Repair by rivet:

The method of connecting outer FRP layer with inner layer, using rivets will still have
delamination in between rivets. But the connection will eliminate waves/movement of
outer layer, to ensure the container will achieves structural integrity.
Large delaminated area can’t be repaired as original condition, as the delaminated FRP
outer layer has already stretched.

When installing rivets, following must be considered:

• Rivets are intended to hold both FRP layers, meaning rivets must grip inner FRP
layer. Drilled hole size will be larger on inner layer, hence high swelling rivets must
be used
• Water tightness: insert sealant into drilled holes prior to riveting.
• Decentralize extended outer layer's waves; Always rivet from point furthest away
from cross directional cut and use the mold to flatten the surplus FRP material.
Effectively removing any waves in the lining

7. Delaminated area:

Check the delaminated area and mark it with removable marker

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

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Page 5 of 17

Classification: Internal
 8. Turn container:

Recommend turning the container as follows:

a. Close all the service valves on compressor
b. Turn the container, the affected side must be on the floor.

9. Cut the outer layer of FRP material:

For both roof and side lining, on any large delaminated area, it is necessary to cut the
outer layer of the FRP material, to be able to remove waves and surplus FRP material. Do
not cut into the inner layer

MCIQ containers Roof lining:

• Cut FRP roof lining as per sketch on page 8

• Remember only, the outer layer of FRP should be cut
• Cut FRP roof lining longitudinally next to inner top side rail aluminum profile. Use
profile as cutting guide
• Cut FRP roof lining at the aluminum rear jamb header cover
• Cut FRP roof lining at the aluminum front header cover
• On FRP panels with large waves, it can be necessary to do one or two vertical cuts
also. Please see the blue cutting lines on the sketch on page 8.
• At each cut of FRP lining there must be a row of rivets 20 mm from cutting line

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 6 of 17

Classification: Internal
 MCIQ containers Side lining:

• Cut FRP side lining as per sketch on page 8

• Remember only, the outer layer of FRP should be cut
• Cut FRP side lining longitudinally, approximately 60 mm parallel from inner top
side rail, due to not good to cut FRP at the bending area. (The inner top side rail
on MCIQ container, is a bended part of side lining)
• If side lining is delaminated above the load line, an extra row of rivets must be
added
• Remove the aluminum lining support at rear end and cut 4 mm off the FRP side
lining
• Cut FRP side lining 30 mm from unit back cover panel
On FRP panels with large waves, it can be necessary to do one or two vertical cuts
also. Please see the blue cutting lines on the sketch on page 8.
• At each cut of FRP lining there must be a row of rivets 20 mm from cutting line,
please see picture below:

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 7 of 17

Classification: Internal
 MCIQ container:

MCIQ containers Side lining:

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 8 of 17

Classification: Internal
 MCIS containers Roof lining:

• Cut FRP roof lining as per sketch on page 10

• Remember only, the outer layer of FRP should be cut
• Cut FRP roof lining longitudinally at the separate inner top side rail.
Ensure when cutting the roof lining longitudinally, that no cut is made into the
inner top side rail profile. Use profile as cutting guide
• Cut FRP roof lining at PVC rear jamb header cover
• Cut FRP roof lining at the aluminum front header cover
On FRP panels with large waves, it can be necessary to do one or two vertical cuts
also. Please see the blue cutting lines on the sketch on page 10
• At each cut of FRP lining there must be a row of rivets 20 mm from cutting line

MCIS containers Side lining:

• Cut FRP side lining as per sketch on page 10

• Remember only, the outer layer of FRP should be cut
• Cut FRP side lining longitudinally at the separate inner top side rail.
Ensure when cutting the side lining longitudinally, that no cut is made into the
inner top side rail profile. Use profile as cutting guide
• Remove the aluminum lining support at rear end and cut 4 mm off the FRP side
lining
Cut FRP side lining 30 mm from unit back cover panel
On FRP panels with large waves, it can be necessary to do one or two vertical cuts
also. Please see the blue cutting lines on the sketch on page 10
• At each cut of FRP lining there must be row of rivets 20 mm from cutting line,
please see picture below

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 9 of 17

Classification: Internal
 MCIS container:

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 10 of 17

Classification: Internal
 MCIS Roof and Side lining:

10. Mold:

Manufacture a mold according to drawings located at the bottom of the bulletin.

Use mold during the repair process:

11. Repair procedure step by step:

Items below refer to the picture with same letter:

a. Apply Polypropylene primer on the FRP cutting area and on app. 1 mm of the FRP cargo
surface.
Apply sealant at the FRP cutting area, press sealant below the FRP to ensure a good
mechanic binding (Due to sealant has a poor adhesion to FRP)
b. Select the correct type of mold
c. Start to use the mold at the middle of the panel, use pressure of two cargo bars to
flatting the FRP lining
d. Mark the drill holes (Pitch: 250 mm)

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 11 of 17

Classification: Internal
 e. Drill 5.0 mm holes, use a drill stop with 5 mm drill depth, for not damage the foam
f. Apply sealant in the drilled holes

g. Rivet the delaminated panel in the mold

h. Move mold one step forward on the delaminated panel, and work to the front and rear
end of container

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 12 of 17

Classification: Internal
 i. Rivet work completed on roof lining

j. Apply masking tape 1 mm from the cutting edge

k. Apply sealant
l. Touch up sealant, by use of spatual and soapy water

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

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Page 13 of 17

Classification: Internal
 Sealant application

Sealant
Sealant

FRP FRP
FRP FRP

m. Remove masking tape

n. For the side inner lining repairs, drill a small (5.0 mm) drain holes at the bottom of FRP
outer layer with the distance of approximately 2 meters.
Drill careful until reach the aluminum foil.
The holes shall NOT be driller though the inner layer of FRP.
Possible water in between inner and outer layer are drained via the drain holes.
o. Use a small screwdriver to ensure inner and outer layer of FRP are separated at the
drain holes.

12. Turn container back to upright condition:

a. Open all the service valves on compressor

b. Wait 24 hours to operate the cooling machine

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 14 of 17

Classification: Internal
 13. Small delaminated area:

Smaller delaminated areas can be repaired by rivet pitch of 250 mm.

To prevent further delamination, least one row of rivets to be installed in the non
delaminated area.
Please see sketch below:

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 15 of 17

Classification: Internal
 14. Mold drawings:

MCIQ manufactured containers: Mold for Roof lining repairs:

MCIQ manufactured containers: Mold for Side lining repairs:

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 16 of 17

Classification: Internal
 MCIS manufactured containers: Mold for Roof lining repairs:

MCIS manufactured containers: Mold for Side lining repairs:

15. Air leak test:

After repair completed, it is recommended to do an air leak test on the container.

For further details, please see the Star Cool CIM 6 CA, Operation and Service Manual on
page 98.

Bjerndrupvej 47 • 6360 Tinglev, Denmark • CVR/SE no.: 13 82 37 74

www.mcicontainers.com • service@starcool.com • +45 7364 3400
Page 17 of 17

Classification: Internal