Intermodal Dry Cargo CNTR/CSC Reinspection Certifier

Cargo Restraint - Restraints

MILVAN containers have an integrated cargo restraint system consisting of eight slotted horizontal rails on the container walls, a pair of slotted vertical rails on the door ends, and 25 movable shoring beams that lock into the rail slots. These components are deigned to stay with the container at all times.

Welder's hammer

A welder's hammer is used to remove slag from weld to determine weld serviceability and to chip away at rusted structures to determine corrosive severity.

Wire brush

A wire brush is used to aid in detecting hidden cracks or corrosion by scrubbing away excessive rust, welding slag, or dirt deposits.

Container Defect - Gouge

A gouge is a cavity in the flooring or other container surface with material scooped out. The width of the gouge is the smaller horizontal direction, regardless of the orientation of the gouge.

49 CFR

49 CFR is the implementation arm of 46 USC, broken into numerous sections by subject/purpose. Parts 450-453 of 49 CFR, SUBCHAPTER B, Safety Approval of Cargo Containers, apply to the use of containers in international traffic: ##Part 450 establishes container marking requirements. ##Part 451 establishes safety approval plate specifications. ##Part 452 establishes container examination requirements. ##Part 453 outlines control and enforcement.

Steel End-opening Container - MILVAN

A MILVAN, or MILSPEC VAN, is a specific type of steel end-opening container. It's a military-owned intermodal freight container conforming to MIL-C-52661 and ISO-standard 1496 Series 1 specifications. Unlike standard end-opening containers, MILVANs have a mechanical restraint system built into their inner structure, and they lack forklift pockets. MILVANS are being phased out in favor of containers requiring fewer parts and less maintenance.

Open-top Container Roof Components - TIR cable

A TIR cable is a plastic-sheathed cable threaded through the welded loops of an open-top container designed to secure the tarp to the container. TIR stands for "Transport international de Marchandises par la Route," and refers to an international customs agreement concerning the transport of goods.

Container Defect - Bend

A bend is a deflection in a structural component causing the component to change direction abruptly from that of its original shape. A severe bend like the one pictured below greatly diminishes the strength of the container and makes the corner fitting unstable.

Caulking gun

A caulking gun is used to make on-the-spot corrections by caulking gaps or voids in the container floor, walls, and seams.

Non-structural Component - Chain and foot bolts

A chain bolt is a spring-loaded bolt used to lock the upper portion of the double doors on a tactical shelter/mobile facility. A foot bolt is a spring-loaded bolt used to lock the lower portion of the double doors on a tactical shelter/mobile facility.

Container Defect - Weld cracks or separation

A cracked, broken, or separated weld between components can seriously compromise a container's structural integrity. The inspector should closely scrutinize component junctions, corners, and edges, especially near the container's end frames and understructure. Suspect areas should be cleaned with a wire brush and tested with a welder's hammer.

Non-structural Component - Customs catch

A customs catch is a rod or plate attached to the center edge of the outer door to prevent the inner door from opening when the outer door is closed. It is used on door assemblies that are not designed with an overlapping edge on the outer door.

Container Defect - Dent

A dent is a localized depression in a panel or structural member made by pressure or an impact. Severe dents compromise a container's rigidity and strength.

Non-structural Component - Door hold backs

A door hold back is a small hook or loop attached to the side of a container to hold the door in the fully open position. It prevents the doors from blowing closed on personnel performing container inspections or maintenance. Not all containers have door holders.

Flashlight

A flashlight improves visibility, especially when examining the understructure or the interior of the container.

Hammer

A hammer, usually a ball-peen or a small sledge, is used to make on-the-spot corrections to small indentations or dents in the container's doors, walls, or roof.

Container Markings - Placard

A hazardous material placard is a diamond-shaped sign affixed to a container transporting hazardous material. A placard may be a rigid sign in a placard holder or a sticker applied directly to the container.

Non-structural Component - High-security hasp

A high-security hasp is a heavy steel enclosure surrounding the door lock hasp designed to prevent someone from cutting the lock off with a bolt cutter or other device. It's used on containers transporting dangerous material or cargo requiring additional security.

Container Defect - Hole

A hole is an obvious puncture through any part of the container. A hole in the container compromises cargo security and may allow moisture to enter the container and damage cargo.

Hole punch

A hole punch is used to punch a hole in the DD Form 2282 decal, indicating the month the inspection was conducted.

Non-structural Component - Joint strip

A joint strip is a formed steel or aluminum strip installed between joints of the container flooring or lining designed to protect and support the edges of the flooring or lining panels.

Ladder

A ladder is used to safely access the roof and upper portion of the container. Help is often required to stabilize the ladder as the inspector ascends and descends it.

Cargo Restraint - Load retainer

A load retainer is a fixture (usually a section of "L" angle steel) welded to the door corner post to provide a strong load bearing surface for cargo restraint dunnage. Many DoD-owned end-opening containers are equipped with a pair of these.

Non-structural Component - Marking panel

A marking panel is a portion of a wall or door panel with a flat surface, designed to display container markings and placards.

Measuring tape

A measuring tape or ruler is used to check dimensional tolerances and container alignment. If a container is "racked," diagonal corner-to-corner wall measurements will not match each other. Measuring tapes used for container inspections must be at least 25 feet long.

Container Defect - Pinhole

A pinhole is a small puncture through any part of the container. This type of defect may not be visible until you close the container doors and look for light "leaking" into the container.

Adjustable Wrench

A pipe wrench is used to make on-the-spot corrections to unacceptable bends in the side rails or other locations on the container. A large crescent wrench may be used in place of the pipe wrench. Adjustable wrenches used for container inspections must be at least 24 inches long.

Container Defect - "Racked" container

A racked container refers to a container that's been twisted or damaged in a way that causes the wall-to-corner alignment to be skewed. A racked container may not be visible to the naked eye, but may be detected by measuring the container sides diagonally and comparing the measurements.

Non-structural Component - Roof panel

A roof panel consists of a corrugated or flat sheet steel, aluminum, FRP, or foam, beam and aluminum honeycomb panel that forms the top surface of the container.

ISO Container

A standardized international shipping container designed to make global material transport safer and more efficient (also called freight container, shipping container, hi-cube container, Conex, or sea can)

Tap hammer

A tap hammer is a small, light-weight hammer designed to aid in detecting sandwich panel delamination on Marine mobile facilities and Army tactical shelters. When a delaminating section of panel is tapped, it makes a dull, hollow sound. A coin may be used in lieu of a tap hammer.

Long straight edge

A tautly-drawn wire, string, or other form of long straight edge is used to determine whether any portion of the container is bowed past the outside edges of the corner fittings. It's also used to determine if the container has been racked (twisted/warped) or if the floor crossmembers are bent. The string used for container inspections must be at least 40 feet long.

Non-structural Component - Three-point latch

A three-point latch is a latch system used on tactical shelter/mobile facility doors to secure the door using three roller cams. This provides additional security and allows the door to be latched from the inside.

Non-structural Component - Threshold plate

A threshold plate, also called a crash plate, is a metal plate mounted forward of the door sill designed to protect the entrance area of the container floor from cargo-handling activities.

Non-structural Component - Ventilator

A ventilator is a device mounted on a side or end wall that enables the container to breathe by allowing air to circulate between outside and the interior of the container.

Non-structural Component - Wall panel

A wall panel is corrugated or flat sheet steel, aluminum sheet, FRP, foam and beam, or aluminum honeycomb material. It forms a side or end wall, protecting cargo from the elements and providing structural rigidity to the container. There are many variations of corrugated wall panels, depending on material and construction.

Non-structural Component - Wall post

A wall post is an intermediate vertical beam riveted or welded to a wall panel, providing rigidity and strength to the wall.

Primary Structural Components - Bottom end rail

Bottom end rails are lateral structural members located at the bottom edge of the front end of the container between the corner fittings.

Primary Structural Components - Bottom side rail

Bottom side rails are longitudinal structural members located at the bottom edge of each side of the container between the corner fittings to form part of the understructure. They provide a means for securing the floor cross members to the container.

International shipping of goods prior to containerization was known as __________.

Break-bulk

Chalk

Chalk is used to mark/circle defects as they are discovered. This helps the inspector prepare the inspection report and also helps repair personnel locate the defects.

Non-structural Component - Anti-rack hardware

Collectively, the locking bars, locking bar mounting brackets, cams, cam retainers, door locking bars, and door locking bar retainers are referred to as anti-rack hardware. Their purpose, in addition to keeping the doors closed, is to strengthen the open end of the container.

Non-structural Component - Flooring

Container flooring is constructed of laminated wood planks, plywood sheets, welded steel or aluminum sheets, sandwich panels, or a combination of metal and wood screwed or bolted to the cross members, forming a load-bearing surface for cargo.

Material Handling Equipment (MHE) - Container rotator

Container rotators are used to gain access to all surfaces of a container, either for repairs or inspection. They allow the container to be rotated by hand once placed into the rotator. A forklift or container handler is required to lift the container onto the rotator.

CSC

Convention for Safe Containers (1972), an international agreement maintaining global container handling and transportation standards. It requires structural safety approval of all internationally-transported ISO containers. It also mandates periodic inspections at specified intervals to ensure safe condition. In the United States, 49 CFR Parts 450 to 453 and Public Law 95-208 mandate compliance with CSC standards.

Primary Structural Components - Corner Fitting

Corner fittings are standardized fittings located at the eight corners of the container. They provide a means of handling, stacking and securing the container. A container must have corner fittings to meet CSC standards.

Primary Structural Components - Corner Post

Corner posts are vertical structural members located at the four corners of the container attached to the upper and lower corner fittings.

Container Defect - Corrosion

Corrosion is the deterioration of metal resulting from a chemical reaction between it and the surrounding environment. The severity of corrosion is measured in stages. If corroded metal can be penetrated by striking the area with a welder's hammer, it's considered Stage 4 corrosion (unacceptable/major defect).

DA Form 2404

DA Form 2404, Equipment and Maintenance Worksheet, is used as a permanent record of each container inspection. It's filled out by transcribing container inspection information from the completed container inspection checklist. Like the inspection checklist, it's a mandatory requirement for every DoD container inspection. Details of this form will be covered later in this course. DA Form 2404 can be found in the appendix of DTR 4500.9-R.

DoD Pub DTR 4500.9-R

Defense Transportation Regulation (DTR) 4500.9-R, Part VI imposes international and federal CSC requirements on containers (commercially-owned or military) transporting DoD material anywhere in the world. Chapter 604 of this regulation identifies CSC container inspector certification requirements.

Container Defect - Delamination

Delamination is a failure in which laminated sandwich panels, fiberglass-reinforced plywood (FRP), plywood, or plymetal panels separate into individual layers, as evidenced by surface bulging and waviness. Delamination compromises panel strength and may allow moisture to penetrate the layers, further weakening the panel.

Personal Protective Equipment (PPE)

Depending on service, command or local work center requirements, some or all of the personal protective equipment (PPE) may be required when performing container inspections: safety glasses, gloves, hard hat, steel-toed shoes, or high-visibility vest.

Flatracks

Flatracks are used for large, heavy cargo that cannot be loaded into a container with fixed sides or walls. They are similar in size and shape to typical steel "box" containers, but they lack a roof and side walls. These containers are being phased out and replaced with container roll-in/roll-out platforms (CROPs).

Non-structural Component - Steps

Folding steps are found on some ISO shelters and are used to gain access to the roof. They must be folded up prior to transporting the shelter.

Understructure Components - Forklift pocket

Forklift pockets are reinforced tunnels situated transversely across the understructure allowing a container to be handled by material handling equipment (MHE). (MILVAN containers do not have forklift pockets.)

Material Handling Equipment (MHE) - Forklift

Forklifts are used to move or lift containers via the containers' forklift pockets. The operator must ensure that the forklift being used is capable of handling the weight of the container.

Deployable Medical Systems (DEPMED)

ISO-compliant containers used to deploy mobile medical resources. They are used to ship and store operating rooms, laboratories and other medical facilities and supplies.

Break-bulk method of transport

Increased handling of goods in port

Containerization method of transportation

Increased shipping speed, reduced shipping costs, and reduced port congestion

Inspection stands

Inspection stands support the empty container off the ground, allowing the inspectors to safely view the container's understructure. MIL-STD-3037 provides inspection stand design specifications. Inspection stand load testing may be required depending upon service, command, or local directives.

Container Inspection Checklists

Inspectors must use a container inspection checklist contained in MIL-STD-3037 to conduct container inspections. Standardized inspection checklists are used to ensure that each container inspection is conducted in a thorough, systematic manner and to clearly document container defects and acceptance or rejection justification.

Feeler/depth gauges

Inspectors use off-the-shelf and locally-fabricated measurement tools to determine whether container gaps, voids, and dents are within standards. A feeler gauge (1" wide by 1/16" thick metal strip) is used to measure flooring gaps while a depth gauge (metal straight edge with a perpendicular point) is used to check the depth of dents. See MIL-STD-3037 for measurement tool specifications.

ISO

International Standards Organization, an international association responsible for developing global standards and specifications for products, services and practices

MIL-STD-3037

Military Standard (MIL-STD) 3037 provides inspection standards for containers transporting DoD material. It is used by civilian and military container inspectors to ensure compliance with international and federal inspection and documentation requirements. MIL-STD-3037 is the primary reference used by inspectors to conduct CSC container inspections.

Open-top Containers

Open-top containers allow room for larger, bulkier items. Instead of a rigid roof, they use a removable canvas or reinforced vinyl tarp supported by portable roof bows. Some have an end door that opens downward to function as a loading ramp. Open-top containers heights vary: Half high (4'3") Two-thirds high (5'8") Full high (8'6")

Container Markings - Container Identification

Per ISO 6346 standards, each container must display the following identification data on both ends, both sides, and the top of the container: owner code, category code, serial number, check digit, county code, and size and type code.

Open-top Container Roof Components - Removable roof bow

Removable roof bows are lateral members placed between the top rails of open-top containers. They support the removable cover (tarp) when in place but can be removed to facilitate the loading of cargo through the top of the container.

Non-structural Component - Roof bow

Roof bows are lateral, non-structural members attached to the top side rails designed to support the underside of the roof panel. Aluminum open-end containers use permanent roof bows to support their rigid roof panel while open-top containers use removable roof bows to facilitate cargo loading through the top of the container.

Non-structural Component - Roof reinforcement plates

Roof reinforcement plates are metal plates designed to protect the roof from damage. Striker plates are attached to each corner of the roof panel, protecting it from misaligned handling equipment. The sling pad, installed in the center of the roof panel, protects it from lowered handling equipment.

Side-opening Containers

Side-opening containers allow easier loading and unloading of large bulky stock, such as bombs. They are similar to end-opening containers except for their door placement and deeper profile on their bottom side rails. Side-opening containers come in two-door or four-door configurations and may or may not have doors on their ends.

Corrosion Stages

Stage 1: minor surface corrosion, red rust, paint blistering Stage 2: beginning of base metal loss, blistering of surface metal Stage 3: significant base metal loss, pin holes may be present Stage 4: sever pitting, irregular areas of surface material eroded away, perforation of base metal

Cargo Restraint - Stanchions

Stanchions are rectangular tubes or pockets along the side rails of flatracks and CROPs. They are used to hold side blocking stakes or dunnage assemblies in position, restraining cargo loads.

Intermodal

Standardized shipping container that can be moved from one mode of transport to another (ship, rail, or truck) without unloading and reloading the contents

DD Form 2282 Decal

The DD Form 2282 decal provides a visual indication that a container is certified to transport cargo. It also identifies the month and year the next reinspection is due. Details of this form will be covered later in this course. A container must be reinspected before its DD Form 2282 decal expires—30 months from the last inspection.

International Safe Container Act

The International Safe Container Act became public law in the United States in 1977. The Code of Federal Regulations, Title 49 (49 CFR) directs all foreign and domestic shipments to comply with CSC standards.

Non-structural Component - J-Bar

The J-Bar is a portion of the exterior edge of the door frame corner that encircles and supports the door hinges. Although the J-Bar and the corner post are manufactured as one piece, they are inspected and repaired as separate components. Corner post defects are much more critical than J-Bar defects.

Non-structural Component - Cam and retainer

The cam is an offset fitting on each end of the locking bar that engages the cam retainer to lock the door. One cam retainer is attached to the door sill and header for each locking bar and cam.

Container Markings - Consolidated Data Plate

The consolidated data plate, or CSC plate, consolidates container data and approval status on one plate attached to a readily-visible area of the container (usually on the door). It displays: ##Country of approval and reference number ##Container type ##Manufacturer I.D. and ISO I.D. number ##Month/year of manufacture ##Maximum gross weight rating ##Allowable stacking weight ##Racking test load value ##Metal stamp or DD Form 2282 decal indicating re-inspection due date

Non-structural Component - Lining

The container lining is plywood or other material attached to the interior side and end walls. It is designed to protect the walls and cargo and to facilitate loading operations. Not all containers have a lining.

Understructure Components - Crossmembers

The crossmembers are lateral structural members attached to the bottom side rails, designed to support the container floor and provide floor strength and rigidity.

Primary Structural Components - Door header

The door header is a lateral structural member located over the door opening between the corner fittings in the door end frame. It provides structural integrity and a means of securing the top door cams, allowing the doors to be secured.

Non-structural Component - Door locking handle and retainer

The door locking handle is attached to the door locking bar; rotating it will open or close the doors. The door locking handle retainer, when engaged, locks the door locking handle in the closed position. It also provides a means to place a lock and/or security seal on the doors.

Non-structural Component - Door panel

The door panel consists of corrugated or flat sheet steel, plymetal, aluminum sheet, sandwich panel, or FRP panel. It's hinged on one side and has locking mechanisms, seals, and other necessary hardware mounted to it. Each container has an inner door that closes first and an outer door that closes over the inner door.

Non-structural Component - Door seal gasket

The door seal is a flexible plastic or rubber gasket attached to the door edges with rivets and adhesive. It provides a waterproof seal between the doors and door frame.

Primary Structural Components - Door sill

The door sill is a lateral structural member located at the bottom of the door opening between the corner fittings in the door end frame. It provides structural integrity and a means of securing the bottom door cams, allowing the doors to be secured.

Understructure Components - Forklift pocket strap

The forklift pocket strap is a plate welded to the bottom of each forklift pocket to help secure the forklift forks while transporting the container.

End Frame Structural Components - Front end frame

The front end frame is a structural assembly at the front end (opposite the door end) of the container consisting of top and bottom end rails joined at the front corner fittings to the front corner posts.

Understructure Components - Gooseneck tunnel

The gooseneck tunnel is a recessed area in the forward portion of the understructure to accommodate transport by a gooseneck chassis (a style of flatbed trailer used to transport ISO containers on land). This feature is more common in forty foot and longer containers.

Non-structural Component - Hinge and hinge pin

The hinge assembly is comprised of a blade permanently joined to the door and a lug integrated into the corner post structure. They are joined together by the hinge pin, allowing the door to pivot open and closed. Hinge pins are often welded on the end to prevent thieves from removing the doors.

Non-structural Component - Lining shield/ kick plate

The lining shield is a thin strip of metal installed at the bottom of the interior walls to protect the lower portion of the lining from damage by material-handling equipment. A kick plate is the same type of shielding, but it's installed on the interior front end wall.

Non-structural Component - Locking bar and mount

The locking bar is a vertical rod mounted to each door panel with cam locks fitted at each end. When rotated, it engages the cam retainers on the doorway frame to lock the doors. On some open-top containers with ramp type doors, this rod is horizontal.

Non-structural Component - Rain gutter

The rain gutter is a channel attached to the door header on some containers to divert water away from the doorway.

End Frame Structural Components - Rear end frame

The rear end frame is a structural assembly at the rear (door end) of the container consisting of the door sill and header joined at the rear corner fittings to the rear corner posts to form the door opening.

Open-top Container Roof Components - Tarp

The tarp (or tarpaulin) is a flexible, waterproof fabric used to cover the top of an open-top container. This cover is referred to as a "tilt" in some countries.

End-opening Container

This container, the most commonly-used by all military branches, is used to ship general purpose dry cargo. There are three types of end-opening containers: Steel Aluminum Fiberglass reinforced plywood (FRP)

Cargo Restraint - Tiedowns, lashing bars and rings

Tiedowns consist of a series of bars or rings mounted on or inside a container to allow the attachment of straps or other cargo restraint devices.

Primary Structural Components - Top end rail

Top end rails are lateral structural members located at the top edge of the front end (opposite the door end) of the container between the corner fittings.

Primary Structural Components - Top side rail

Top side rails are longitudinal structural members located at the top edge of each side of the container between the corner fittings and end frames. They provide a means for securing the roof panels to the container.

46 US Code (USC)

United States Code (USC) Title 46, Appendix - Shipping, Chapter 34, Safe Containers for International Cargo, gives the Secretary of Transportation the authority to administer the International Safe Container Act. It establishes penalties—fines of up to $5,000 per day—for non-compliance.

Material Handling Equipment (MHE) - Container handler

Usually identified by the manufacturer (TEREX, Super Stacker, KALMAR), container handlers move containers by lifting them at the corner fittings. Extreme caution must be exercised when working near container handlers due to the crushing hazard posed to personnel.