Guidelines to.. Plywood Floor Repairs - Maersk · PDF filePlywood Floor Repairs Centre ... STS Code Repair Name Full board replacement 1160*1000 6525 Replace Plywood ... per pc. 6520

Guidelines to.. Plywood Floor Repairs

Centre Equipment & EMR – March 2014

This document shall be used by EMR teams and EMR

vendors as an update to MCIC v6, Section 6 “Repairs

to Plywood Floors”, describing what are the

acceptable repairs in all cases.

Document Reference: CENEMR/2014/002/MRS046

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Contents

• Floorboard Specifications

• Floorboard Types

• General Repair Guidelines

• Floorboard Damage/Repair Cases

• STS Codes Summary

• Improper Repairs


Floorboard Specifications

• Floorboard material can be plywood, bamboo or a mixture of plywood and

bamboo.

• Overall floorboard thickness is 28 mm (min. 19 plies).

• Plywood species that be used include: Eucalyptus, Poplar, Birch, Beech,

Pine, Larch, etc.

• Maximum moisture content shall not exceed 14%.

• Outer three plies on each side are made of Apitong or Keruing.

• Wood is chemically treated according to the requirements of the

Commonwealth of Australia, Department of Health, Australian Quarantine

and Inspection Service (AQIS) [Timber Components Treated – TCT

Certificate].

• Plywood floors shall be FSC certified (Forest Stewardship Council).

• Floorboard shall pass the following tests:

• IICL Short Span Test (3.1 in IICL Performance Standard for Plywood

Floor Panels – IICL TB001).

• Bending Strength and Elastic Modulus (4.9 in GB/T 19536 2004).

• Boiling Test (GB/T 19536 – 2004).

• ISO 1496 Floor Strength Test (Truck Load of 7,260 kg).

Information in this section can be used when starting a tender for EMR vendors, and as well during MAuS when auditing existing vendors.


Floorboard Types (Can be sporadically found in Maersk Line container fleet)


General Repair Guidelines

• Delaminated floorboard is defined as: damage observed down to the 4th ply layer (e.g. top 3 plies are missing + min. 1

loose ply).

• Any floor repair must always involve the full width of the board. Standard width is 1160 mm for all container sizes.

• Floorboards over the outriggers in 40ft containers shall also be repaired using full width replacements. Standard width

for those boards is 636 mm.

• Floorboard repairs involving unsecured edges are not allowed at any time.

• Steel patches are never acceptable as a permanent method of repairing. Holed floorboards should be repaired by dowels

(up to 25 mm hole diameter) or replaced when observed, according to the cases found in this document.

• Floorboard with finger cracks shall be repaired, only if one of the following conditions is fulfilled: visible sign of impact on

the opposite side – damage to an adjacent component (rail, cross member, etc.) – visible bowing on the floor’s opposite

side – hollow sound when affected floor is tested by hammer. If repair-worthy, follow the guidelines in this document.

• Full board replacement (1160x2400 mm) [Case 9] is not a requirement unless the damage is covering over 75% of the

board area. If less, there are different codes with dimensions to choose from according to [Case 8].

• If the damage is not described in this document, apply common sense. As a rule of thumb, replaced board should cover

at least 3 support members (cross member, outrigger, tunnel bolster, sill or FLP cross member). Furthermore, original

(undamaged) floorboard should also cover at least 3 support members after the repair is made. If damage is within the

edge of a floorboard, repair should be extended to this edge.


Floorboard Damage Cases


Case 1 Size Design Damage Location

Any SHORT board at the rear (door) end Within the short floorboard

DAMAGE REPAIR

Repair Dimensions (W*L) mm

STS Code Repair Name

Full board replacement 1160*1000 6525 Replace Plywood Section 1160x1000mm (Case 1/3/8)




Any LONG board at the rear (door) end In the first rear board and within the first 4 cross members from the door sill

DAMAGE REPAIR



Partial replacement: extended door sill + min. 4 cross members

1160*1300 6523 Replace Plywood Section 1160x1300mm (Case 2/8)




20ft. SHORT board at the front end Within the short floorboard

DAMAGE REPAIR



Full board replacement 1160*1000 6525 Replace Plywood Section 1160x1000mm (Case 1/3/8)




20ft. LONG board at the front end Between front sill and 2nd cross member

DAMAGE REPAIR



Partial replacement: front sill + min. 2 cross members

1160*650 6521 Replace Plywood Section 1160x650mm (Case 4/5/6/8)




20ft. Any design Floorboard above or adjacent to the forklift pocket (FLP)

DAMAGE REPAIR

1 FLP Cross Member + 2 FLP Cross Members + 2 normal Cross Members 1 normal Cross Member



Partial replacement: total covering 3 cross members.

1160*650 6521 Replace Plywood Section 1160x650mm (Case 4/5/6/8)




40ft. Any design Wide floorboard attached to tunnel bolster.

DAMAGE REPAIR



Partial replacement: area covering bolster + min. 2 cross members

1160*650 6521 Replace Plywood Section 1160x650mm (Case 4/6/8)




40ft. Any design Small floorboard over the outriggers.

DAMAGE REPAIR



Partial replacement: area covering 3 support members: (bolster + min. 2 cross members) OR (min. 3 cross members)

636*750 636*1600

6520 6522

Replace Small Plywood Section 636x750mm (Case 7) Replace Small Plywood Section 636x1500mm (Case 7)




Any Any design Any other damage where the other cases do not apply.

DAMAGE REPAIR



Partial replacement: area covering min. 3 cross members

1160*650 1160*800 1160*1000 1160*1300 1160*1600 1160*1900 1160*2100

6521 6526 6525 6523 6527 6528 6529

Replace Plywood Section 1160x650mm (Case 8) Replace Plywood Section 1160x800mm (Case 8) Replace Plywood Section 1160x1000mm (Case 8) Replace Plywood Section 1160x1300mm (Case 8) Replace Plywood Section 1160x1600mm (Case 8) Replace Plywood Section 1160x1900mm (Case 8) Replace Plywood Section 1160x2100mm (Case 8)




Any Any design Similar to Case 8 but bigger damage area, beyond 75% of panel area.

DAMAGE REPAIR



Full floor panel replacement. 1160*2400 6524 Replace Full Plywood Panel 1160x2400mm - Case 9



Summary of STS Codes

STS Code

Repair Name Status Case(s) Qty. Pcs.

Time per pc.

6520 Replace Small Plywood Section 636x750mm New 7 4 0.5 hr.

6521 Replace Plywood Section 1160x650mm Renamed 4/5/6/8 4 0.8 hr.

6522 Replace Small Plywood Section 636x1500mm Renamed 7 4 0.7 hr.

6523 Replace Plywood Section 1160x1300mm Renamed 2/8 2 1.5 hr.

6524 Replace Full Plywood Panel 1160x2400mm Renamed 9 6 2.1 hr.

6525 Replace Plywood Section 1160x1000mm New 1/3/8 4 1.2 hr.

6526 Replace Plywood Section 1160x800mm New 8 4 0.9 hr.





Improper Repairs

Workmanship Material

Gap should be max. 1mm. Screw head should be min. 16mm.

Wrong location of screws – or wrong size of plywood, resulting in failure to secure the floorboard from one edge.

Wrong material used! Poor floorboard quality.

Workmanship/Quality 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.

Documents

Guidelines to.. Plywood Floor Repairs - Maersk · PDF filePlywood Floor Repairs Centre ... STS Code Repair Name Full board replacement 1160*1000 6525 Replace Plywood ... per pc. 6520