Technical Bulletin

DRY1903 30-08-2019

Guidelines for Sectioning repairs on headers and sills

SAFETY NOTE!
Procedure is to be carried out in accordance to local
safety regulations and by use of adequate PPE.
1. INTRODUCTION
This document provides guideline as to perform sectioning repairs on Maersk Line owned container dry fleet and Open
top fleet (Modes 03 & 05). Shall be used by EMR teams and EMR vendors in conjunction to latest version of MCIC
describing what are the acceptable repairs in all cases.

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 2. DESIGN TYPES
2.1 Front header

Type one (one formed front header) - Most common

Type Two (combined structure with square tube)

2.2 Rear header

Rear Header, normally combined by two components. The difference between below two types is the different
weld joint.
Type 1 – Most common

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 Type 2

2.3 Rear Sill

Rear Sill （Large）

For such type, there is no section repair need in most cases.

Rear Sill （Others less common)

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 2.4 Front Sill

Front sill (20ft) Front sill(40ft)

3. REPAIR PROCEDURE
Damage situation

View from back side

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 1) Cut the damage area according to below criteria, noticing:
-Section overlap must be at minimum 2 times the height of the sectioned profile

-If an insert would end within 150mm of another vertical weld, it must be extended to that welding.

-Type A is only allowed near the corn fittings connections.

-For Type B, Type C section to be selected based on damage

Example:

Example of different sectioned profile in right/left side of one replacement component

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 2) Prepare the replacement components
There are two methods to prepare the replacement components and repair shop can choose any of them base on
own practice but our recommendation is the second integrity material.
-Cut one integrity tube with different lengthen (must comply with the lengthen requirement above)

3) Bevel adjoining surfaces for components to a combined 60° angle (30° angle from the perpendicular on each side of
the joint) to ensure complete weld penetration.

4) Tack weld to fix the position, the new component must be flush with the original rail and allowing no more than 2
mm clearance between adjoining surface.

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 5) Continuously weld to the exterior of the sill.

6) Apply the paint base on the requirement in ML repair manual.

20ft front sill

Damage status

1) Cut the damage area according to below criteria

*Sectioning must be at least 300mm in length.

*If a Section would end within 150mm of another vertical weld, it must be extended to that welding.

In summary, the minimum distance of any vertical weld should be 2 times height of sectioned profile.

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 *Remain size limitation of cut parts

MCIC & IICL - No special provision to the remaining portion of the vertical web after cutting. For vertical web,
recommend to keeping the original existing portion more than 15 mm.

For the remain height on the web, shall be kept 15mm and cut to angle is acceptable if
possible to keep.

For other plane, no limitation.

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 The insert must be flush with the original rail and allowing no more than 2mm clearance between adjoining surfaces.

2) Tack weld to fix the position

3) Continuously weld to the exterior of the sill.

For front sill inserts, double sides weld is necessary to ensure structural integrity.

4) Apply the coat on repaired surfaces in accordance with ML repair manual.

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 3. Summary of STS Codes
sts Repair Name Max Quantity Man Hour
2550 Front Sill - Section - 150 mm 3 0,9
2551 Front Sill - Section - 300 mm 2 1
2552 Front Sill - Section - 450 mm 2 1,1
2553 Front Sill - Section - 600 mm 2 1,3
2554 Front Sill - Section - 900 mm 1 1,5
2555 Front Sill - Section - 1200 mm 1 1,7
2556 Front Sill - Section - 1500 mm 1 1,9
2557 Front Sill - Section - 1800 mm 1 2,2
4550 Rear Sill - Section - 150 mm 3 1,4
4551 Rear Sill - Section - 300 mm 2 1,5
4552 Rear Sill - Section - 450 mm 2 1,7
4553 Rear Sill - Section - 600 mm 2 2
4554 Rear Sill - Section - 900 mm 1 2,3
4555 Rear Sill - Section - 1200 mm 1 2,6
4556 Rear Sill - Section - 1500 mm 1 2,9
4557 Rear Sill - Section - 1800 mm 1 3,3
2450 Front Header Incl. Extension Plates - Section - 150mm 3 1,1
2451 Front Header Incl. Extension Plates - Section - 300mm 2 1,2
2452 Front Header Incl. Extension Plates - Section - 450mm 2 1,3
2453 Front Header Incl. Extension Plates - Section - 600mm 2 1,6
2454 Front Header Incl. Extension Plates - Section - 900mm 1 1,8
2455 Front Header Incl. Extension Plates - Section - 1200mm 1 2
2456 Front Header Incl. Extension Plates - Section - 1500mm 1 2,3
2457 Front Header Incl. Extension Plates - Section - 1800mm 1 2,6
4450 Rear Header Incl. Extension Plates - Section - 150mm 3 1,3
4451 Rear Header Incl. Extension Plates - Section - 300mm 2 1,4
4452 Rear Header Incl. Extension Plates - Section - 450mm 2 1,6
4453 Rear Header Incl. Extension Plates - Section - 600mm 2 1,8
4454 Rear Header Incl. Extension Plates - Section - 900mm 1 2,1
4455 Rear Header Incl. Extension Plates - Section - 1200mm 1 2,4
4456 Rear Header Incl. Extension Plates - Section - 1500mm 1 2,7
4457 Rear Header Incl. Extension Plates - Section - 1800mm 1 3,1

9. Supervision and Oversight

Contact your ML EMR personal for repair recommendations, repair examples, comments or questions.

Workmanship, Quality, and safety issues should be highlighted during the audits or the normal visits
to the vendors (post-repair / previous-repair inspection). Raw material inspection should also be
done during the audit and more importantly, shall be monitored by the vendors themselves.

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