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FM 38-701

DEPARTMENT OF THE ARMY FIELD MANUAL FM 38-701MARINE CORPS ORDER MCO P4030.21DEPARTMENT OF THE NAVY PUBLICATION NAVSUP PUB

DEPARTMENT OF THE AIR FORCE PAMPHLET AFPAM(I) 2DEFENSE LOGISTICS AGENCY INSTRUCTION DLAI 4145.2

PACKAGING OF MATERIEL

PACKING

DEPARTMENTS OF THE ARMY, THE NAVY, THE AIR FORCE,AND THE DEFENSE LOGISTICS AGENCY

DISTRIBUTION RESTRICTION: Approved f or public release; distribution is unlimited.



FM 38-701/MCO P 4030.21D/NAVSUP PUB 503/AFPAM(I) 24-209/DLAI 4145.2

*FM 38-701

MCO 4030.21D

NAVSUP PUB 503

AFPAM(I) 24-209

DLAI 4145.21 December 1999

DEP ARTMENTS OF THE ARMY,

NAVY, AND AIR F ORC E, AND THE

DEFE NSE LOGISTICS AGENCY

P ACKAGING OF MATERIE L

PACKING

CHAPTER PAGE

I N T R O D U C T I O NPU RPOSE .................................................. ....................................................... ....... 1

SCOPE ....................................................... ....................................................... ....... 1

REFERENCES.......................................................................................................... 8

CHAPTER 1 - P ACKINGGENERAL .................................................. ....................................................... .......1-1

SEQUE NCE OF PACKING OPERATION .................................................. ................1-1

DETERMINATION OF PACKING REQUIREMENTS................................................1-3

ITEM CHARACTERISTICS .................................................... ...................................1-3LOAD CHARACTERISTICS ................................................... ...................................1-7

MODES OF TRANSPORTATION ..................................................... .........................1-7

STORAGE CONSIDERATIONS.............................................. ...................................1-8

DESTINATION AND FIELD CONDITIONS..............................................................1-9

FUNCTIONS AND S ELECTION OF SHIP PING CONTAINERS ...............................1-9

ARRANGEMENT OF CONTENTS............................................................................1-9

BLOCKING AND BRACING .................................................. ...................................1-11

APPLICATION OF BLOCKING AND BRACING....................................... ................1-12

STRAPP ING REINF ORCEMENT FOR CONTAINERS ..............................................1-33

CUSHIONING..........................................................................................................1-35

PACKING PROBLEMS ................................................. ............................................1-51

PACKING SMALL, LIGHTWEIGH T ITEMS ...................................................... .......1-53

CLEARANCE BE TWEEN ITEM AND CONTAINER ..................................................1-54WEATHERPROOFING THE PACK...........................................................................1-55

TESTI NG OF PACKS ................................................... ............................................1-59

MARKING OF PACKS .................................................. ............................................1-68

ECONOMY IN PACKING ....................................................... ..................................1-68

PARCEL POST REQUIREME NTS ................................................... .........................1-72

*This field manual supersedes DLAM 4145.2, Vol II/TM 38-230-2/NAVSUP PUB 503, Vol

II/AFP 71-16/MCO P4030.21C, Pa ckaging of Mater iel – Pa cking (Volum e II), J un e 1977

DISTRIBUTION RESTRICTION: Approved for public release; distribution is unlimited.



F M 38-701/MCO P 4030.21D/NAVSUP P UB 503/AFP AM(I) 24-209/DLAI 4145.2

ii

CHAPTE R 2 - FIBE RBOARD AND PAP ER BOARD CONTAINERS

FI BERBOARD BOXES .....................................................................................................2-1

TRIPLE -WALL CORRUGATED FIBE RBOARD BOXES (ASTM D 5168) ...................2-31

CHAPTE R 3 - WOODEN CANTAINERS AND PALLETS

CONTAINE R MATERI ALS .............................................................................................3-1

NAILED AND LOCK-CORNER WOOD BOXES (PPP-B-621)......................................3-7

NAILIN G REQUI REMEN TS ...........................................................................................3-20CLE ATED-PANEL BOXES (GEN ERAL)........................................................................3-30

CLE ATED PLYWOOD BOXES (PP P-B-601).................................................................3-34

BOXES,, WOOD-CLE ATED P ANELBOARD .................................................................3-42

WOOD-CLEATED, SKIDDE D, LOAD-BEARING BASE BOXES (MIL-B-26195).......3-42

WIREBOUND WOOD BOXES (PPP-B-585)...................................................................3-50

CLASS 3 MILITARY OVERS EA......................................................................................3-53

PALLE TS (GENERAL).....................................................................................................3-59

FOUR-WAY POST CONSTRUCTION PALLETS (MIL-P-15011).................................3-62

FOU R-WAY (PARTIAL) STRINGE R CONSTRU CTION P ALLETS (NN-P-71) ..........3-62

MAINTE NANCE OF PALLE TS ......................................................................................3-62

CHAP TER 4 - BAGS AND SACKS

NE ED FO R BAGS AND SACKS ......................................................................................4-1

BAGS DEFI NE D...............................................................................................................4-1

SACKS DEFI NE D ............................................................................................................4-1

SH IP PI NG BAGS AND SACKS .......................................................................................4-1

COTTON MAILING BAGS (A-A-2714) ...........................................................................4-1

PROCUREMEN T..............................................................................................................4-3

CUSHIONED PAPER SHIPPING SACKS (A-A-160, A-A-1588)...................................4-3

A-A-160 (CUSHION ED WITH POS T CONSU MER RE COVERED MATERIAL)........4-3

A-A-1588 (CUSH IONE D WITH CLOSE D CE LL P LASTIC F ILM) ..............................4-5

BURLAP SH IP PI NG BAGS (A-A-881)............................................................................4-7

CHAPTE R 5 - PAILS AND DRUMS

DESCRI PTION , CLASSIF ICATIONS, AND SELE CTION F ACTORS ........................5-1METAL SHIPPING AND STORAGE DRUMS (MIL-D-6054).......................................5-3

METAL DRUMS (STANDARD) (MISCELLANEOUS)..................................................5-9

FI BER DRUMS .................................................................................................................5-12

CHAPTE R 6 - CRATES

INTRODU CTION TO CRATES .......................................................................................6-1

CRATE MATERIALS........................................................................................................6-18

WOOD CRE ATES, OP EN AND COVERE D, MIL-C-52950 (GEN ERAL).....................6-29

TYPE I, STYLE A --HE AVY DUTY CRATE (MIL-C-52950)..........................................6-34

TYPE I, STYLE B--LIGHT DU TY CRATE (MIL-C-52950)............................................6-35

TYPE II, STYLE A--HEAVY DUTY CRATE (MIL-C-52950) .........................................6-37

TYPE III , STYLE B--LIGH T DUTY CRATE (MIL-C-52950).........................................6-40

TYPE IV, STYLE A--HEAVY DUTY CRATE (MIL-C-52950) ........................................6-43TYPE V, STYLE A--HE AVY DU TY (MIL-C-52950) .......................................................6-43

TYPE V, STYLE B--LIGH T DU TY CRATE (MIL-C-529502).........................................6-48

ASSEMBLY INSTRU CTION S (MIL-C-52950) ...............................................................6-58

OPE N WOOD CRATE S, MIL-C-3774 (GE NE RAL)........................................................6-60

OPEN BOLTE D CRATE S (MIL-C-3774) ........................................................................6-60

OPEN NAILE D CRATES (MIL-C-3774) .........................................................................6-72

SHEATHED WOOD CRATES, MIL-C-104 (GENERAL)...............................................6-84

ASSEMBLY (CLASS 1 CRATES ) ....................................................................................6-115

CRATE, SLOTTE D ANGLE, STEE L O R ALUMIN UM (MIL-C-9897) .........................6-141




iii

CHAPTE R 7 - CONSOLIDATION AND UNITIZATION FO R SH IP MENT

AND USE OF CARGO CONTAINERS

CONSOLID ATION AND UN ITIZATION FOR SHI PME NT .........................................7-1

PALLE TIZING UNI T LOADS (MIL-HD BK-774) ...........................................................7-2

SHRI NK FILM AND S TRETCH FILM PALLETIZATION ...........................................7-6

CONSOLIDATION CONTAINERS (GENERAL)...........................................................7-6

BOXES, SHIPPING INSERT CONSOLIDATION, MIL-B-43666 (GENERAL)...........7-6

TYPE I, WOOD CLEATED PLYWOOD CONSOLIDATION INSERT BOX(MIL-B-43666)................................................................................................................7-8

TYPE II, PLYWOOD WIREBOUND CONSOLIDATION INSE RT BOX

(MIL-B-43666)................................................................................................................7-11

TYPE III, F IBERBOARD CON SOLIDATION INSE RT BOX (MIL-B-43666)..............7-11

PACKING CONSOLIDATION CONTAINER.................................................................7-13

PACKING SE MI-PERISH ABLE S UBSIS TEN CE ITEMS ............................................7-14

CARGO CONTAINE RS (GEN ERAL)..............................................................................7-16

USE OF MILVANS AND SE AVANS ...............................................................................7-18

SHIPMENT OF HAZARDOUS MATERIALS.................................................................7-21



F M 38-701/MCO P 4030.21D/NAVSUP P UB 503/AF J P AM(I) 24-209/DLAI 4145.2

1

INTRODUCTION

PURPOSE AND SCOPEP U R P O S EThis publication contains information on the fundamental principles and

appr oved meth ods and t echn iques used in t he pr otection of militar y supplies

and equipment against deterioration and damage during shipment and

stora ge. It is publish ed as an official document for use in operations and in

the training of military and civilian personnel from all segments of the

Department of Defense (DOD) and supporting agencies, as well as for

interested indust rial personnel. It conta ins inform ation based on

specifications, standards, and other pertinent documents, current as of the

date of prepar ation a nd coordination of the pu blication.

NOTE

For Air Force use, the pu blicat ion is n on-directive in na tur e.

S C OP EThis manual emphasizes the importance of packing of military supplies and

equipment. It contains detailed informa tion concerning the requirement s to

accomplish packing operat ions. The requirem ent s include use of exter ior

shipping containers; the assembling of items or packs into the container;

anchoring, blocking, bracing, and cushioning of items or packages within the

container; weatherproofing; strapping of containers; the testing of exterior

packs; palletization and unitization of loads; parcel post; and related subject

mat ter. Genera l exterior mar king in accordance with MIL-STD-129 is

discussed.

C HANGES AND P ROVISIONS

Changes or revisions to this manual are due to major changes in packing

concepts, policies and doctrine, and revision of specifications and other

official publications, will be made on a continuing basis, as required.

Informa tion contained h erein is curr ent a s of J un e 1996.

Users are encouraged to submit recommended changes or comments to

improve th is man ua l. Commen ts should be keyed to the specific page,

paragraph, and line of the text in which the change is recommended.

Reasons should be provided for each comment to insure understanding and

complete evaluation. Commen ts should be prepared using DA Form 2028

(Recommended Changes to Publications and Blank Forms) or appropriate

service form and forwarded direct to Dean, U.S. Army Ordnance School of

Military Packaging Technology, ATTN: ATSL-MPT, 360 Lanyard Road,

Aberdeen Proving Ground, MD 21005-5003.

OBJ ECTIVES OF M ILITARY P ACKAGING

The objectives for a chieving un iform pa cking of items of militar y sup ply are

to--

• Insure optimum life, utility and performance of materiel through

prevention of deterioration or dam age.

• Support t he ma teriel readiness posture of DOD.




2

• Provide for efficient receipt, storage, inventory, transfer and issue of

materiel.

• Assure that marking requirements are kept at the minimum

necessary for effective identification, handling, shipment and storage.

• Effect economies by requiring the use of packs which yield lowest

overall cost to the total DOD distribution system consistent with

known or anticipated shipment handling and storage conditions.Considera tions will include--

ο Minimization of mater ials, methods of preservation, a nd

documentation.

ο Accomplishm ent with optimum a mount of au tomated

operations.

ο Minimum weight an d cube.

ο Use of modular conta iners.

ο Ha ndling by u nitized load configur ation.

ο Use of containerization.

ο Exploitation of new ma terials, meth ods, an d techniques.

ο Disposability of packaging materials.

H AZARDS E NCOUNTERED IN TRANSPORTATION, H ANDLING, AN D STORAGE

Military supplies and equipment must be protected against pilferage and

damage due to force and exposure, not only until they reach their ultimate

destinat ion, but un til the items are placed int o actual use or service. Force

an d exposur e will reduce the u seful lifespan of the item or cause th e item to be

dam aged beyond rep air. The objective of packing is to exten d the lifespa n of

the item so that depreciation starts, not when it leaves the manufacturing

plant , but wh en it is placed into service.

F o r c e

Damage may result from hazardous forces encountered in transportation,

ha ndling, an d stora ge (figur e 1). Tran sportat ion ha zards involve forces

encoun tered thr ough rail, tru ck, boat, or air shipments. The dama ge caused

can result from abru pt st art s, stops, vibrat ion, an d jolting.

Ha ndling ha zards involve th ose dama ging forces received th rough loading,

un loading, and han dling dur ing stora ge opera tions. Exam ples of ha ndling

where dama ge often occurs ar e--

• Manual handling--dropping and puncture.

• Forklift truck handhng--dropping and puncture.

• Cargo nets--dropping, cru shing, an d wr acking.

• Grab h ooks--cru shing an d pun ctu re.

• Slings--cru shing, dr opping, a nd wracking.

•

Conveyers--jarring, sm ash ing, and dropping.Storage hazards involve those forces resulting from the crushing effect of

superimposed loads th rough sta cking.

E x p o s u r e

Exposure to the different climatic conditions and weather hazards, such as

high hu midity, rain, salt spra y, extreme cold, dry inten se heat , and t he cycling

of these weather conditions, will tend to accelerate the breakdown or

deterioration of unprotected items.




3

Figure 1. Ha zardous forces encountered in tra nsporta tion handling, an d storage.

Pi l f e r age

Theft of military supplies and equipment while in transit or storage is a significant

problem for the military. Small items of high value are especially vulnerable to pilferage

and should be protected as much as possible through packing techniques.




4

C o u n t e r m e a s u r e s To H a z a r d s O f P a c k

Items which are packed properly will resist the damaging effects of force and

exposure. Force is coun ter acted by--

• Using r igid shipping conta iners.

• Immobilizing the item with in the conta iner th rough an choring,

blocking, and bracing.• Damping forces th rough t he u se of cushioning m ater ials an d devices.

• Reinforcing shipping containers with metal and nonmetallic

stra pping or reinforcement ta pe as appropriate.

Exposure is coun tera cted by the use of--

• Weather-resistant shipping containers.

• Waterpr oof bar rier ma terials in various applications.

NECESSITY FOR A P ACKAGING P OLICY

To attain economy, efficiency, and uniformity in packing, and to provide a

un iform pr ocedure in conn ection with procur ement , the services an d a gencies

of th e Depart men t of Defense must h ave a common packing policy. This isprovided by the Department of Defense (DOD) 4140.1-R, Materiel

Management Regulation.

M ILITARY R EGULATIONS

The Joint Regulation AR 700-15/NAVSUPINST 4030.28C/AFJMAN 24-204/

MCO 4030.33D/DLAD4145.7, applies to all Department of Defense compo-

nents (Army, Air Force, Navy, Marine Corps, and the Defense Logistics

Agency) respons ible for packa ging an item t hr oughout it s life cycle.

This regulation on th e packaging of ma teriel implements DOD 4140. 1-R an d

covers packaging requirements, American Society for Testing and Materials

Standards (ASTM) specifications, levels of protection along with policies and

procedures for Performan ce Oriented Pa ckaging (POP) an d th e protection of

electrostatic discharge sensitive items.

M ILITARY P ACKAGING LEVELS OF P ROTECTION

Concep t o f Mi li t a r y Leve l s o f P r o t ec t i on

In regard to requirements for packing, the military services for many years

relied heavily on the term s "domestic" an d "overseas". Exper ience proved

that for military purposes, these words were vague generalities with no

clear-cut mean ing to them. Suppliers were often per plexed when confronted

with overseas r equirement s for items destined for domestic installations. It

was not apparent to them that the domestic destinations were merely initialreceiving points for projected overseas shipments, or that storage and

handling conditions were severe enough to justify an overseas type of

packing regardless of destinat ion. To permit th e military services to state

their requirements more objectively, the concept of levels of protection was

adopt ed. As defined in MIL-STD-2073-1C, levels of protection are a means

of specifying the level of military p reservat ion an d pa cking th at a given item

requires to assure that it is not degraded during shipment and storage (see

figur e 2). Specific levels of pr otection a re a s follows:




5

Figure 2. Examples of protection.

• M i l i t a r y l eve l o f p r e s e r va t i on . Preservation designed to protect

an item during shipment, handling, indeterminate storage, and

distribution to consignees worldwide.

• Mili t a r y leve l s of pa ckin g .

o Leve l A. Protection required to meet the most severe worldwide

shipment , handling, and storage conditions. Level A pack mu st,

in ta ndem with t he a pplied preservation, be capable of protecting

material from the effects of direct exposure to extremes of

climate, terrain, operational and transportation environments.

Examples of situations which indicate a need for use of a Level A

pack are: War Reserve Material, mobilization, strategic and

theater deployment and employment, open storage, and deck

loadin g. Exa mples of cont ain ers used for Level A packin g




6

requirements include, but are not limited to, overseas type wood

boxes and plast ic and meta l reusable containers.

o Leve l B. Protection required to meet moderate worldwide

shipment , ha ndling, an d storage conditions. Level B pack must,

in ta ndem with t he a pplied preser vation, be capable of protecting

mat erial not directly exposed to extremes of climate, t erra in, an d

opera tiona l tra nsporta tion environm ents. Exam ples of situat ionswhich indicate a need for use of a Level B pack are: security

assistance (e.g., Foreign Military Sales (FMS)) and containerized

overseas shipmen ts. Exam ples of conta iners used for Level B

packing requirements include, but are not limited to, domestic

wood crates, weather-resistant fiberboard containers, fast pack

containers, weather-resistant fiber drums, and weather-resistant

paper a nd m ulti-wall shipping sacks.

C o m m e r c i a l P a c k a g i n g . Commer cial packaging is defined as t he m ater ials

and methods used by the supplier to meet the requirements of the

distribution systems serving both DOD and commer cial consumers. The

requirements of MIL-STD-2073-1C shall only be applied to the packaging of

items that are expected to enter the military distribution system.Commercial packaging is to be used to the maximum extent possible for all

other items. Items n ot going into stock shall be packaged in accordance with

ASTM D 3951, Stan dar d P ractice for Commer cial Pa ckaging.

Commercial packaging will be acceptable for any level of protection when the

technical design of the package meets all conditions of the level of protection

specified. It will be ma rk ed to th e level it meet s. Use of comm ercial

packaging is contingent u pon no increase in packaging changes, size, weight,

or delay in delivery.

Bulk practices used in interplant a nd intr aplant movements or shipments t o

jobbers are not acceptable unless they are the usual trade practices for

individual commodities such as coal, textiles. petroleum, and subsistence.

The packaging details will be incorporated into standardization and

acquisition documen ts when applicable.

NATO S TANAG 4280, LEVELS OF R EQUIREMENTS FOR P ACKAGING

Participating nations agree to adopt the NATO levels of requirements -

defined in this STANAG as the basis for negotiation for the procurement of

packaged mater iel between nat ions. In defining levels of requiremen ts it is

necessary to take into account: The characteristics of the environment and

constraints imposed by the environment; the technical considerations to

define package tests; the four levels of packaging used in NATO; and, it also

shows comparison of these NATO levels against the nearest nationalpackaging requirement.

Type o f Load . The term "type of load" refers to the physical characteristics

of the item, including the nature of the item as it contributes to the support

of, or dam age to the conta iner. The sam e kind of conta iner can be designed

to provide adequate protection to various items by adjusting the

constru ctional requiremen ts. This may result in a light, medium, or

heavydut y container, as necessary. The design of th e shipping container t o

be used is influen ced by the typ e of load. Ther e ar e thr ee types of loads : Type

1, Type 2 an d Type 3. The t ypes of loads will be ment ioned un der the various

shipping containers and in section I (figure 3).




7

Figur e 3. Types of loads

Type 1 - easy load . The load is a single item or single interior container

which provides complete and uniform support to all faces of the shippingcontainer. Bulk practices used in interplan t and intra plant movements or

shipments to jobbers are not acceptable unless they are the usual trade

practices for individual commodities such as coal, textiles, petroleum, and

subsistence.

Type 2 - ave r age l oad . The load is composed of more than one item or

interior container which give some support to all faces of the shipping

container . The contents ar e of moderate density and relatively stur dy. Some

examples are goods in metal cans which are not packed in an interior

container, bottles individua lly cushioned, an d ha rdwa re in cart ons.

Type 3 - Diff icu l t load . The load gives little or n o support t o the sh ipping

conta iner. The cont ents can be extremely heavy, very fragile, very irregularin sh ape, bulk m ater ials which a re free to shift. and flow, or a combinat ion of

several of these factors. Some exam ples are rivets, bolts, and n uts, delicate

instruments and machined part s and assemblies.

E CONO MY IN P ACKING

The military concept of economy in packing is to obtain maximum output of

adequa tely protected items at a minimum cost. Economy measu res,

consistent, with the degree of protection required by an item or package

should be of prime concern to individuals engaged in the establishment of

packing requirements, an d to personnel in cha rge of, or performing packing




8

operat ions. Significant savings can be accomplished by reducing the ta re

weight, cubage, and packing cost of a commodity through proper

reengineering of the unit and exterior containers, use of newly developed

mat erials, an d employment of altern ate met hods and techniques.

R E F E R E N C E S

Throughout this manual, packing materials, equipment, processes, methods,etc., are referred to by their common names together with the appropriate

specificat ion, sta nda rd, or other p ublication symbols. Copies of specificat ions

and other documents required by activities of the Defense Logistics Agency,

the Depar tmen t of th e Army, Navy, and Air Force, and t he Mar ine Corps a re

obtained from supply sources thr ough established chann els. Copies of

specifications, standards, and drawings required by contractors connection

with specific procurement functions should be obtained from the procuring

activity or as directed by th e cont ra cting officer. Milita ry and Feder al

Specifications and Standards are available from: Standardization Document

Order Desk, 700 Robbins Avenue, Building #4, Section D, Philadelphia PA

19111-5094. Informa tion pamphlet titled "A Guide for th e Private In dustr y"

provides more detailed informa tion a nd is ava ilable upon requ est.




1-1

CHAPTER 1

PACKING

GENERAL

P ACKING OF GENERAL SU P P L I E S

Some commodity items require preservation by procedures and materials

described in FM 38-700/MCO P4030.31D/NAVSUP PUB 502/AFJPAM 24-

237/DLAI 4145.14, Packaging of Materiel – Preservation, which provide unit

containers suita ble for shipment without fur th er packing. Other items may

require fur ther packing in containers suitable for shipment . This cha pter

relates to the packing of commodity items directly in shipping containers

with whatever protection is required to prevent damage in shipment,

han dling and storage. The container alone can not always provide full

protection for military items. Items must be properly anchored, braced,

blocked, or cushioned in th e cont ainer t o provide adequ at e protection. A

container is often blamed for damage to its contents when the cushioning,

blocking, or bra cing ar e at fault (fig. 1-1). Ever y packing operat ion, including

the final closure, strapping, and marking of the container, must be carefully

planned and executed to ensure that the contents will arrive at its

destinat ion in a u sable condition.

P ACKAGING OF H AZARDOUS ARTICLES

Commodities classified as hazardous materials come within the scope of

TITLE 49 Code of Federal Regulations which incorporates Department of

Transportation Regulation for the Transportation of Explosives and other

Hazar dous Articles by all modes. Inter na tiona l Shipments mu st be packaged

in accordance with the International Air Transport Associations DangerousGoods Regulation (IATA) and the International Maritime Organization

Dan gerous Goods Code (IMDG) codes. In addition, ha zar dous mate rials

which a re to be shipped via milita ry aircraft mu st be packaged in a ccorda nce

with the joint service manual AFJMAN 24-204/TM 38-250/NAVSUP PUB

505/MCO P4030.19/DLAM 4145.3, Preparing Hazardous Materials for

Military Air Shipmen ts.

SEQUENCE OF PACKI NG OPE RATION

The general sequence of military packing is divided into a series of basic

operations which may include some or all of the following steps, not

necessarily in the order given below:

D e t er m i n e t h e P a c k in g R e q u i r e m e n t sKnowing the item characteristics helps to determine the protection required

and the best way to provide it through the use of an adequate container,

suitable blocks, braces, and cushions, and a ppropriate bar rier m ater ials. This

study will include consideration of the characteristics of the item, its size,

shape, fragility, etc.; the types of loads (easy, average or difficult); the mode

of transportation (rail, ship, truck, or aircraft); the storage facilities (covered

or un covered); the dest ination (domestic or overseas in t he ar ctic, temperat e,

or tr opic zones); an d th e levels of protection r equir ed.




1-2

Se l ect t h e Con t a i ner

Select and use an exterior container that will comply with the requirements

outlined in applicable cha pter s of th is ma nu al. This selection should consider

all factors pertinent to giving adequate protection at the minimum cost such

as the characteristics and limitations of the container; its initial cost and

upkeep expenses; its weight and cube; its availability or obtainability in

appr opriate quant ities; an d its reusability.

Prepa re protec t i ve barr iers

Prepare an appropriate barrier to give weatherproofing protection not

obtaina ble from th e conta iner a lone.

I n s e r t an d S ecur e t h e I t em t o t he Con t a i ner

Insert the item a nd secure it to the conta iner to contr ol or prevent m ovement

by mea ns of adequ at e cushioning, blocking, an d bra cing. The distinction

between cushioning and blocking is that cushioning permits controlled

movement of the item within the container, while blocking and bracing

usu ally is designed to prevent m ovement of the item within th e container .

Figure 1-1. Dama ged items as a r esult of improper/inadequa te packing.




1-3

S eal the Ba rr ier i f Used

Seal the bar rier mat erial by mean s of adh esives, heat seals, pressur e seals, or

sealing tape to provide weatherproofness of the seams, joints, and closures

equal to tha t of the ba rr ier mat erial itself.

C lo s e t h e C o n t a i n e r

Close the container following the detailed requirements outlined in the

section of this m an ual which describes th e cont ainer selected.

R e i n f o r c e t h e C o n t a i n e r . Reinforce the container with metal or plastic

strapping or reinforced tape as appropriate and as required for the container

selected.

M a r k t h e S h i p p i n g C o n t a i n e r . Mark the container as appropriate to

identify the cont ents a nd to ensur e movement to its destinat ion.

DETERMINATION OF P ACKING REQUIREMENTSThe different types of items procured by the Depart ment of Defense r equire a

wide var iety of packing operat ions. Items var y from str ong, ru gged ones tha t

fit the container well and require no cushioning, blocking or bracing, to

others that are irregular in shape, delicate, or fragile, and require special

cushioning, blocking or bra cing.

B ASIC F ACTORS

To determ ine packing requirem ents, several ba sic factors mu st be considered,

namely, the item characteristics, the load characteristics, the mode of

transportation, the storage and handling facilities, the destination and field

conditions.

B ASIC R E F E R E N C EThe basic reference for blocking, bracing, and cushioning is MIL-STD-1186,

Cushioning, Anchoring, Bracing, Blocking, and Waterproofing, with

Appropriat e Test Methods. This stan dar d, appr oved by th e Depart ment of

Defense and mandatory for use by the Armed Forces, provides general

requirements and procedures concerning the arrangement of the contents

within th e shipping cont ainer for t he pr evention of physical damage.

SC O P E O F MIL-STD-1186

The standard covers common packing requirements which may be omitted

from detail specifications for items or categories of items when this standard

is referen ced in the deta il specificat ion. It does not cont ain requ iremen ts for

shipping containers, themselves or for unit packing, both of which also

provide physical protection.

ITEM CHARACTER ISTICSThe first step in any packaging operation is a careful study of the item to be

packed. It is necessary to consider the shape, size, weight, strength, and

degree of fragility of th e item in all directions. The ava ilability of moun tin g

provisions, the degree of disassembly permissible for shipment, corrosion

prevention requirements and special use requirements which affect the

packing opera tions mu st a lso be considered.




1-4

SH A P E

The shape of the item to be packed is an important factor to consider in

designing blocking and bracing. A regular-shap ed item with rectan gular

surfaces requires a minimum of blocking, while an irregular-shaped item

with uneven surfaces, including projections, often require an elaborate

blocking system. Cur ved surfaces requir e car efully fitt ed blocking to preven t

damage caused by concentrated stresses at contact points, and to distributeinternal forces over a greater area of the faces of the container (fig 1-2).

Long, slender items, particularly if heavy, exert a tremendous concentrated

force on th e ends of th e container du ring ha ndling. This force may be

counteracted by securely blocking the item to the sides, top, or bottom of the

container, and by increasing the thickness of the ends of the container (fig

1-3). Relatively heavy, irregular -sha ped small items pr esent a pa rticularly

difficult pr oblem when t hey mu st be cush ioned a s well as blocked. Gener ally,

in solving this problem, it is desirable to even out the surfaces by means of

pads an d blocking to increase the bearing area. This in tu rn decreases the

load p er u nit a rea of bear ing on th e cushion (fig 1-4).

S IZE AND WE I G H T

A large item may require more extensive blocking and larger amounts of

cush ioning th an a smaller one. The blocking ma y be necessary to bridge the

relatively wide spans of the container faces, or it may be required to

distribute the cushioning over larger area s of the item. Since the impact

force developed by the abrupt stopping of a moving object is directly

proportional to its weight, the weight of an item is very important in

considering the blocking an d cushioning. In stu dying the item, consider th e

distribution of the weight with respect to the size and bearing ar eas. Where

the weight is concentrated, it may be necessary to distribute it over a larger

area . This may be done by tran sferring some of it from one conta iner face to

the edges or corners of the container by the use of end blocks.

Figure 1-2. Inter ior blocking for an irregular sh aped item.




1-5

Fi gu r e 1-3 . Us e o f co r r uga t ed fi be r boa r d pa ds and l i ne r .

F i g u r e 1 -4 . I n t e r i o r b l o ck i n g t o p r o t e c t c on t a i n e r a g a i n s t e n d t h r u s t .




1-6

STRENGTH AND F RAGILITY

Some items are rugged enough to withstand greater stacking loads and

ha ndling forces tha n th eir container s. Various components of vehicles and

tanks, in particular, require little protection against shipping hazards, but

are placed in conta iners for ease of ha ndling, stowage, and storage. On th e

other h and, there a re nu merous items th at require the maximum protection

afforded by packing mat erials. Equipmen t is considered ru gged or highlyresistant to shock when bracing and blocking within the container is all that

is needed for protection. Items th at r equire cush ioning for pr otection ar e

considered to be fragile. The degree of fragility of an item determines the

amount and type of cushioning required to protect it from damage during

han dling and shipment . Some items are inh erent ly strong and ru gged except

for one or more fra gile compon ent s. When t he fragile componen ts cann ot be

removed for separat e packing the entire item m ust be treat ed as fragile, even

though t his may resu lt in an u na voidably large, cumber some pack.

AVAILABILI TY OF MOUNTING P ROVISIONS

An importa nt factor to consider in packing is the availability of brackets a nd

holddowns on the item that can be used to mount it within the container.

Frequently, it is possible to mount an item within the container by using the

same bra ckets and h olddowns tha t ar e used for positioning an d securing it in

place when it is permanently installed. Mounting facilities should be

examined to determine if they are adequate, especially if the container is

likely to be tipped on end (fig 1-5). Compr essors, en gines, engin e componen ts,

generators, starters, an d carburetors are often secured in this ma nner.

Figure 1-5. Moun ting facilities of item m ust be adequat e.




1-7

D ISASSEMBLING OF AN ITEM

Items should be thoroughly investigated to determine if disassembly of

simple parts can reduce the size of the conta iner r equired an d/or simplify the

packaging. Proper au th orization must be obtained before disassembling any

portion of an item that would require technical skills or special tools to

rea ssemble, rea lign, or recalibra te. The disassem bly of simple-to-rem ove

component s with stan dard tools (i.e.., han dles, wheels) does n ot require priorauthorization.

D i sa s s e m b l e d P a r t s

When practicable, items should be disassembled to afford protection of

components, attachments, and accessories against damage and pilferage and

to reduce cubage. Disassembled par ts should be wrapp ed, packaged,

anchored, braced, blocked, or cushioned within t he sh ipping container so tha t

parts or protective devices within the shipping container cannot be damaged

by mutu al cont act. Disassembled par ts sh ould be clearly and legibly mar ked

as to identity an d proper location on the assembled item. All fasten ers

removed dur ing disassembly should be secur ed in one of th e mating par ts. A

part should not be removed from an assembly unless it can be reassembled

rea dily in t he field with out special tools.

CAUTION

Proper authorization must be obtained before disassembling any

portion of an item that would require technical skills or special

tools to reassemble, realign or recalibrate. Disassembly of simple-

to-remove components such as handles, wheels, etc., requiring

stan dar d tools, does not n eed aut horization.

SPECIAL P ACKING R EQUIREMENTS

Reusable and other special purpose containers usually require special

consideration of the packing of the conten ts in th e container . For instan ce, inreusable containers, the blocking and cushioning must be arranged so that it

may be easily removed, and when replaced, it will adequately protect the

contents. However, reusable and special purpose containers should be

considered for use, especially if their use results in reduced weight, cube, or

cost. For examp le, th e reusa ble cont ain er for a missile nose cone, shown in

figure 1-6 while expensive to procure, may more than pay for itself through

its reusa bility and its designed protection featu res.

LOAD CHARACTER ISTICSThe proper selection of the shipping container for a given load is of the

utm ost importa nce. The kind of conta iner mu st be determined by the weight,

size, sha pe, and fra gility of th e load. To aid in th is selection, th e various

loads have been classified as Type 1-Easy Load, Type 2-Average Load, andType 3-Difficult Load. (See fig. 3 of the I nt roduction.)

MODES OF TRANSP ORTATIONThe mode of tra nsporta tion is an importan t factor in deter mining th e packing

requiremen ts. The hazar ds of ha ndling an d shipping vary greatly between

motor, ra il, ship, or aircra ft. As an exam ple, th ere could be consider able

difference in the amount of handling that an item being transshipped from

truck to rail to ship would receive, and the amount of handling an item

delivered by air freight would receive. Likewise, an item




1-8

Figure 1-6. Protection featu res of a r eusable missile container.

to be delivered by airdr op would require m uch more pr otection t ha n one to be

delivered by tr uck.

STORAGE CONSIDERATIONSTo assure serviceability of the contents after prolonged exposure to

deteriorating elements, not only the supplies, but the packing materials

which enclose them m ust be protected. There ma y be a considera ble periodfrom the time the material leaves the man ufacturer u ntil it is used. It may

be stored outd oors in domestic depots, then shipped to staging ar eas or ports

of embark ation to await tr an sportation overseas. Fina lly arr iving, it may

again be st ored in depots or su pply areas wh ich could be improvised shacks,

nat ive hut s, tents, caves, or even in th e open. At oversea supply points, the

packs are often broken open and smaller intermediate packs distributed to

forward ar eas. On the other ha nd, items may be shipped directly from the

supplier to th e user with a minimu m of delay. In th is insta nce, th e protection

provided by the pack could be considerably reduced from the amount

required for t he oversea pack.




1-9

DESTINATION AND FIE LD CONDITIONSThe ultimate destination of items is generally unknown when they leave a

packing facility. Some item s may be used domest ically while the rest will

eventua lly go overseas. They may be shipped to the a rctic regions, the

island s of th e seas, or th e tropical jungles. They ma y be subjected to the cold,

heat, humidity, aridity, or the extreme temperature changes of the various

regions, all of which must be considered in planning the pack to assure

adequate protection through the time of delivery and after arrival at

destinat ion when they m ay be su bjected t o unfavorable field conditions.

FUNCTIONS AND SELECTION OF SH IP P ING CONTAINERS

F UNCTIONS

A shipping container is an y exterior box, cra te, dru m, etc., which is required

to enclose one or more items d ur ing tr an sit or storage. The ba sic functions of

a shipping container are to protect the contents and to provide for ease of

han dling. Shipping containers a ssist in th e han dling of a nu mber of items by

consolidation, and of a single item which is difficult to handle. The degree of

protection derived from the shipping container depends upon its type, thematerials used in its fabrication, its construction features, its final

destination, the nature of the contents, and the anticipated hazards.

Chapters 2 through 7 of this manual contain information on approved

containers for military shipments and should be consulted when making

selection of th e app ropriate containers.

SELECTION

The shipping container is usually established by specifications, directives,

technical orders, or oth er aut horized publications. Where a group of

containers is authorized, or when the proper container is not specified, the

packing supervisor is responsible for the selection of the appropriate

container. They must ba se their selection u pon the ph ysical cha ra cteristics of

the item; its destination; whether domestic or overseas; the level of protectionrequired; the type of load; the initial cost of the container; the weight and

cube of the container; the simplicity, economy and ease of assembly and

closure; the availability; and need for reusability of the container (fig 1-7).

Nailed wood boxes or similar heavy wooden containers will not be used

unless fully justified by past experience or environmental, geographical, or

security considerations.

ARRANGEMENT OF CONTENTSThe contents of a pack should be arranged within the shipping container so

as to provide maximum pr otection to its contents an d the cont ainer. Where

applicable, the arrangement should permit a container fabricated of

materials that will result in low tare weight, smallest practical cube,

convenient ha ndling, an d suitability for palletization. Conten ts should

completely fill the container or be secured therein with suitable clearance.

Packs of like items should contain like quantities and should be uniform in

size, shape, an d weight.

MOVABLE P ARTS AND P R O J E C T I N G P ARTS

Articles with moving external parts or projecting parts that might become

damaged by shock or vibration encountered in shipment should have these

part s ma de secure against movement by mea ns of blocking, bracing, tiedown,

or other adequate provisions, or should be disassembled, if practicable.




1-10

Figur e 1-7. Conta iner selection factors.

SEGREGATION OF P ACKED C ONTENTS

So far as p racticable, contents of shipping conta iners sh ould be segregated in

th e following order: (a) th e ord er on th e packing list; (b) items of th e sam e

contract; (c) items of the same National Stock Numbers; and (d) items of the

same Feder al Supply Class.

C ONVERSION OF TYP E 3 LOADS

Where practicable, type 3 loads should be converted to type 1 or type 2 loads.




1-11

BLOCKING AND BR ACING

B LOCKING AND BRACING DE F I N E D

Blocking and bracing is the process of providing physical and mechanical

protection t o an item by mean s of mat erials, oth er th an cushioning ma terials,

intended to prevent any free movement of the item within the container, and

distribute or transfer concentrated loads of the item to larger areas of other

faces of the cont ain er.

F UNCTIONS OF BLOCKING AND B RACING

Items which do not completely fill the shipping container should be blocked,

bra ced, an chored, or other wise immobilized with in the conta iner . Blocking

and bracing should be used to secure items or components so that they will

not shift within a container; to make irregular shaped items fit a regular

container; to distribute th e weight of irr egular items over all edges and faces

of the container; to protect projections from injury; to prevent projections

from damaging the barrier or container; to provide space for spare parts or

make room for desiccant; and to reinforce weak portions or mountings.

Blocking and bracing modifies the original shape of an item so that it isprotected adequa tely an d so th at it fits the cont ainer. The mat erials used for

this purpose differ from cushioning in that they are not intended to absorb

shocks. Item s having legs or oth er projectin g portions which may become

loose or broken, or which m ight pun cture th e conta iner, must be supported by

adequa te blocking and bra cing. The blocks an d braces should be applied

against portions of the container that are strong enough to resist forces

tending to distort them. Likewise, th e bracing should be arr an ged to

distribute forces to several reinforced sections of the surface of the item (fig

1-8). Items with movable par ts, items mounted sprin gs or other flexible

supports sh ould be braced secur ely to prevent m ovement , except wh ere su ch

mounting is part of the package cushioning or is designed to protect against

shock an d vibrat ion dur ing shipment.

Figure 1-8. Blocking an d bracing to prevent movement.




1-12

ABRASION P ROTECTION

Protection should be provided when the surface of the item in contact with

the blocking an bracing can be damaged by relative motion between the

contacting surfaces or could become corroded as a result of such continuous

cont act. Pr otection aga inst a bra sion should be provided for highly finish ed or

easily marred surfaces by wrapping or covering with cushioning material.

Surfaces that might be damaged by contact with cushioning material shouldbe sepa ra ted by a covering of noncorr osive pa per conforming t o MIL-P-130 or

greaseproof barrier material conforming to MIL-B-121, grade A.

AP P LICATION OF BLOCKING AND BRACING MATER IALSThe materials selected for all blocking and bracing, the design and

application of the blocking and bracing should be compatible with the load to

be supported and the size, shape, and strength of bearing areas of the item.

The heavier the load needing support, the stiffer and stronger the materials

for blocks an d braces must be. Hen ce, th e choice of ma ter ials depend s upon

the size and sh ape of th e area s against which t he blocking an d bracing will be

placed, as well as the size and weight of the item being secur ed. Since a

shipping container may be dropped on any of its faces or corners, blocks andbraces must be designed to withstand the thrust and impact applied on any

direction. The choice of ma ter ials used for blocking a nd br acing vary widely.

The chief materials used are corrugated fiberboard in cells, trays, pleated

pads, and flat pads, for relatively lightweight items or for supplementary

prim ar y blocking of hea vy item s. Wood, plywood, rigid plast ic foam s, an d

meta l are used as t he prima ry blocking ma terials for lar ge and hea vy items.

F i b e r b o a r d

Open -end cells an d tra ys of corr uga ted fiberboar d. When used a s blocking,

corrugated fiberboard must be designed to fit the bearing area of the item to

support an d evenly distribute the load. Common forms of corr ugat ed

fiberboard blocking are die-cuts, open end cells, trays, pleated pads, and flat

pad s (fig 1-9). Fr equen tly, var ious combina tions of th ese forms ar e employed.They can be used to provide spaces for, and restrain the movement of,

disassembled parts, as well as provide openings for bags of desiccant.

Genera lly, cells an d tr ays should be held in shape with tape or sta ples.

Figure 1-9. Cells an d tra ys made of corru gated fiberboard.




1-13

Figur e 1-10. Incorrect an d correct direction of corr uga tion.

Those surfaces of the cell or tray which are perpendicular to the contacting

surface of the item are called bracing supports and are the load bearing

members. No bracing support allowances should be ma de for the other

surfaces. To utilize all of the str ength of th ese bracing sup ports, they should

bear directly on th e item. The weight of the item mu st be exerted in th e

same direction a s the corr ugat ions. If not, the item is ina dequat ely supported

and d ama ge may result (fig 1-10). Open-end cells and t rays should be used

for blocking and bracing deep recesses; bridging long projections; providing

spaces for disassembling parts, accessories, and dessicants; and providing

clearan ce between item and conta iner. Bracing supports sh ould bear directly

on the a rt icle. Allowable loads for bra cing su pport s of open-end cells loadedin th e flut e direction sh ould be in accorda nce with ta ble 1-1. If flut e direction

is at right a ngles to the direction of th e load, t he a llowable loads should be 50

percent of th e valu es of ta ble 1-1. Tra ys should be scored a nd folded par allel

to the flute direction an d should n ot exceed 4 inches in h eight .

C ORRUGATED F IBERBOARD F ORMS

Corrugated fiberboard used for blocking and bracing should conform to

ASTM D 4727. Blocking and br acing forms sh ould be loaded in th e direction

parallel to the flutes wherever possible. The cutting, slotting, scoring, and

folding of fiberboard blanks to make blocking and bracing supports or forms

shall be such as to assur e proper fitting a nd distr ibution.

F OLDED P AD S

Folded pads of corrugated fiberboard may be used for blocking greater loads

tha n are feasible to support with cells and tra ys. The pads should be

designed to fit against a flat surface (flat pads) or along an edge (corner

pads). Conn ecting webs between flat pads should always contact the

container a nd not the item. All scores and folds should be made at right

angles to th e flute direction. Flat pa ds should be a minimu m of 2 inches

wide. Portions of folded pads in direct conta ct with t he item ar e bearing

area s. The maximum loads for these bearing areas should be in accordance




1-14

Table 1-1. Allowable loads for corru gat ed fiberboard . Colum ns loaded in the

flute direction.

Material

Allowable loads p er linea l inch

of bra cing su pport or column

Height u p to

4 inches

Height over

4 inches

Pounds Pounds

Double-faced fiberboard :

200-pound burst ing strength



2

2.5

3

1

1.5

2

Double-wall fiberboard :




2.5

3

4

1.5

2

2.5

Triple-wall fiberboard :

1,100-pound burst ing st rength 5 4

Note. When a greater load is imposed than that permitted by the table, use wood

blocking and bracing

with ta ble 1-2. Accordion folded pads ha ve grea ter r esista nce to brea kdown

than open end cells because the load is spread over a large area rather than

on bra cing support s. Accordion folded pads with tight folds distr ibute th e

load more evenly to th e conta iner . The conn ecting web between t he folded

pleats should be placed in contact with the container rather than the item.

Creases for accordion folded pads should be made across the corrugations,

and t he pleat should be at least 2 inches in width. If necessary, a pleat 1 1/2

inches wide may be made, but extreme care must be exercised when folding

the pad to prevent cru shing the corru gations. Tape should be used to keep

accordion folded pad s in shap e. The load bea rin g capa city of a pa d is based

on the initial compressibility of th e corrugat ed mater ial. Increasing the

number of pleats does not increase the safe load limit; numerous pleats

increase the cushioning value only. Wide or long items a re better supported

by several accordion folded pads, placed side by side, than by one pad having

extremely wide folded pleats.

F LAT P AD S

Flat pads of corrugated fiberboard may be used to block very shallowprojections, su ch as hin ges or slight offsets on su rfaces; to level off projectin g

screw heads; to fill in the space between ends of inner flaps of slotted

fiberboard boxes to provide additional protection to contents at top and

bottom of boxes; an d to sepa ra te items with in a conta iner . Allowable load s

should be in a ccorda nce with table 1-2. Maximum a llowable loads per squar e

inch of bearing area on a flat pad are the same as those for a pleated pad.

Flat pa ds can be slotted t o form par titions, or th ey may be die cut or pun ched

to fit items or irregular sh ape. Figure 1-11 shows the assem bling of slotted

fiberboard par titions.




1-15

Table 1-2. Allowable loads for folded corn er a nd flat p ads of corru gat ed fiberboar d

Flu te design Maximum a llowable load for bear ing

areas

Pounds per squa re inch

A-flut e (36"3 corru gat ions per foot)

B-flut e (50"3 corr uga tions per foot)

C-flut e (42"3 corr uga tions per foot)

2.0

3.0

2.5

Note. The flat crush resistance of the corrugations shall determine the load that may be carried

in flat loading of corr ugat ed fiberboar d. This shall not be constru ed to meet the bur sting

strength of the mat erial.

Figur e 1-11. Assembling of slotted fiberboard pa rt itions.

C O R N E R P AD S

The use of corner pa ds m ade of multiple layers of corru gated fiberboar d sh all

comply with t he load requirem ents of table 1-2. The pads sh all provide

required clearances and support for rectangular shaped items or for an inner

box in wh ich items ar e packed.

TUBES

Fiberboard tubes should be used as blocking when items mounted on an

auxiliary base ar e packed on fiberboard boxes. The bottom of the tu be shall

contact th e top of the au xiliary base an d th e top of the tu be sha ll contact th e

top inside surface of th e conta iner. The flutes sh all be oriented in th e top-to-

bottom direction of the t ube. The weight of th e item plus au xiliary base, in

pounds, divided by the perimeter of the tube, in inches, sha ll not exceed th e

appr opriate values given in table 1-2 for column heights over 4 inches.

C ORRUGATED F IBERBOARD L I N E R S

A liner is a continuous pad, bent to fully contact two or more inner faces of a

container . Liners ar e used to reinforce a conta iner a gainst crush ing by forces

imposed during stacking, or to take the place of two or more flat pads. A liner

may also be used as a holddown for base mounted items weighing not more

tha n 20 pounds. The creases in a liner should be made par allel to th e




1-16

direction of the corru gations of th e fiberboard, in order t ha t t he r esistance to

forces ordinarily encounter ed in sta cking be th e greatest .

C O R N E R P OSTS

Fiberboard corner posts should be used to reinforce the shipping container

an d provide blocking for plat form -mount ed equipmen t. The flutes shou ld be

oriented in th e top-to-bott om direction. The bottom end of th e corner postshall bear u niformly on the plat form, a nd t he t op end of the corner post sha ll

bear on the inner flap of the conta iner or top member of a crate. Corn er

posts, when installed, must so interlock with the contents and other inner

padding pieces in order not to become displaced du ring tr an sportation.

WOOD OR P LYWOOD

Wood or plywood may be used alone or in combination for blocking and

bra cing. Wood or plywood blocking an d bra cing mem bers should bear

against only those parts of th e packed item capable of withsta nding the

applied dyna mic forces or should bear a gainst blocking pads or pressur e

str ips tha t adequ at ely distr ibute th ese forces. Wood or plywood blocking an d

bracing should be designed to permit easy removal without damage to the

item. Both wood and plywood are u sed for blocking an d bracing becau se of

their h igh stren gth-weight r atio, genera l availability, and ea se of cut ting an d

fasten ing. Lumber ha s certa in weaknesses, such as low splitting resistan ce

parallel with the grain, and a tendency to shrink or swell with change in

moistur e content.

Plywood has h igh resistan ce to splitting an d h igh dimensional st ability with

cha nges in moistu re content . Because they are more resistan t to splitting

than solid wood, plywood panels are more often used in thinner dimensions

than lumber, and are readily nailed or fastened with screws near the edges.

Plywood is more apt to have a lower moisture content tha n lum ber because of

the manner in which it is manufactured and stored. Plywood, being

constructed of alternate plies at right angles to each other possesses moreuniformly distributed strength properties than lumber. When considering

lumber a nd plywood of compara ble sizes and quality, it is generally tru e th at

the strength properties of lumber parallel to the grain are greater than the

respective strength properties of plywood parallel to the grain of the face ply.

It is also true that the strength properties of lumber perpendicular to the

grain are generally less than the respective strength properties of plywood

perpendicular t o the gra in of th e face ply.

WOOD

Wood members of each size an d type u sed in t he blocking an d bra cing sh ould

be tested for moisture conten t. Stru ctura l members (those subject to critical

bendin g stresses) sha ll conform to class 1. All other blocking an d bracing

mem bers sh all conform to class 3. When ever possible, wood blocks or br acesshall be placed so that the load is applied against the end grain of the

member. En ds of braces shall be socketed or fitted an d secur ed into

appr opriate notches in load-bearing members.

P LYWOOD

Plywood u sed for blocking an d br acing sh ould conform t o A-A-55057.




1-17

WOOD B LOCKING AND BRACING

The species of woods differ greatly in strength and related properties and,

accordingly, have been separated into four groups. Certain species, such as

those of Group IV, excel in toughn ess and shock r esistance, but care m ust be

exercised in n ailing th em to avoid splitting. Other species, such as south ern

yellow pine and Douglas fir of Group II, are high in bending strength and

stiffness ; an d na iling is a lesser problem. The char acter istics of th e groups of wood may be used to advantage in various forms of blocking and bracing (fig.

1-12). Thin pieces of lumber split more easily than thick pieces; hence, thin

pieces for blocking should be avoided if possible. If the dim ensiona l limits of

the item require t ha t t he blocking be th in, it is preferable to use plywood.

MOISTURE C ONTENT

The moisture content of lumber employed as blocking and bracing material

should not exceed 19 percent nor be less than 12 percent of its oven dry

weight at t he time of fabrication. Shr inka ge is objectiona ble because it allows

movement of the item and the item may actually break loose. Moisture in

lumber is objectionable because it is apt to evaporate into the pack, thus

raising th e hu midity of the pa ck and causing corr osion of meta ls or d ecay of

organ ic mat erials.

CAUTION

Lumber, plywood, or other hygroscopic materials should never be placed in direct

contact with critical metal surfaces since such materials tend to absorb and

reta in moisture n ext to the sur faces, finally cau sing corrosion. Pr ovide always a

water-vaporproof barrier between any critical metal surfaces and hygroscopic

packing materials, and a waterproof or moisture-resistant barrier between all

meta l sur faces an d h ygroscopic mat erials.

DE F E C T S I N BLOCKS AND B RACES

Wooden members used for blocking a nd bracing ar e often subjected to greatstress a nd careful consideration must be given to any weaken ing defects. If

the member functions as a beam or column, defects such as divergence of

gra in, kn ots, splits and decay should be avoided. This is especially import an t

if the defect is located near the center of the piece, because of the great

reduction in shock resistan ce. If a piece with a kn ot is used, the load is

placed so that the k not is in compr ession a s shown in y, Figure 1-12. Lumber

having kn ots of a diamet er exceeding one-fourth th e width of the piece should

not be used (fig 1-12). The slope of gra in in each piece should n ot exceed 1

inch in 10 inches of length , or splitt ing is likely to occur . Decayed wood is

avoided un der a ll circumstan ces because ther e is not way of determining h ow

much th e decay may ha ve weaken ed the wood. For additional inform ation on

wood knots, see chapter 3 an d figure 3-3.

Si ze o f Wood Br aces o f Ho l ddown s

Braces or holddowns must be of sufficient size to withstand the shocks

encoun tered. The size of a brace varies with t he weight of the item, th e

length of th e brace, an d th e type of loadin g. Table 1-3 used with figure 1-13

gives the recommended allowable load in pounds for the various sizes of

braces an d the various types of loading. For example, assume tha t the

weight of the item is 60 poun ds, the length of the brace is 24 inches, and th e

type of loading is the third type illustrated in figure 1-13 (loading in the




1-18

Figur e 1-12. Applicat ion of wooden blocks an d bra ces.




1-19

Table 1-3




1-20

Figur e 1-13. Types of loadin g (use with ta ble 1-3).

center 4/5 to 1/3 of the u nsu pported length of th e brace). For th is type of

loading, multiply the weight of the item by the factor 3/4, as shown in figure

1-13. Three-fourth s times 60 equa ls 45. In the column h eaded "Length of

brace in inches", of table 1-3, find 24 inches and read to the right until a

value near 45 is found. The heading for th is colum n shows that t he proper

size of member and direction of loading is a 1 x 2-inch member used on edge,

or a 1 x 4 inch member used flatwise.

P OSITIONING LOADS ON BLOCKS AND BRACES

When wood blocking and bracing is used to secure heavy items, place the

block so that the load r ests on th e end grain of the piece, whenever possible.

If this cannot be done, the load should bear on the edge gra in. When so

placed, the ma ximum str engt h of th e brace is used (fig 1-14). Since wood is

relatively stable in dimension along the grain, there is little effect from

shrink age or swelling with a cha nge in moistu re cont ent. The brace should, if

possible, have its na rrow face against the item so that its maximum stiffness

is utilized. If a larger bear ing area is required, an d it becomes necessary to

have the flat face of the brace against the item, the size of the brace against




1-21

th e item, must be increa sed (ta ble 1-3). Lum ber which is relat ively wide for

its thickness must be reinforced throughout its length to prevent twisting or

buckling.

USING LUMBER AS A MOUNTING BAS E

If an item is to be secured to a base, and plywood is not available, use

dimensiona l lumber. Bases of dimensiona l lumber sh ould be constru ctedwith sufficient cleats at right angles to the grain of the baseboards, and

fastened with clinched nails to prevent the boards from splitting at the bolt

holes. Stren gth of th e bases must be adequa te to withsta nd any rough

han dling the p ack ma y be likely to receive.

SECURING LUMBER B LOCKING

Securing lumber blocking properly is the most essential factor in blocking

an d bracing. Wooden braces positioned between two faces of a cont ain er

should never be secured with end grain nailing, toenailing, or similar

meth ods, nor should th ey ever be insert ed into notches cut into the container

faceboard s. Instea d, the braces should be secur ed by cleats fastened to the

faces of th e conta iner with a sufficient nu mber of clinched na ils. When

pressures are great or an increased nailing area is required, backup blocks

are used to reinforce the cleats and give increased n ailing area . When

pressur e is from more th an one direction, a pocket cleat ar ra ngement is used

to hold the braces in position z fig 1-12. The backu p blocks are positioned

with their end grain in contact with the brace in order to make use of the

high stren gth property of wood in compression par allel to the grain. The

cleats and backup cleats | fig 1-12 are secured with clinched nails properly

staggered at intervals along their length. Sometimes, however, bolts are

used to fasten these mem bers in place. This is especially desira ble when the

entire weight of the item thrusts against the block, or when the cleat

supports a framework at tached t o one or more faces of the cont ainer.

Figur e 1-14. Positioning load accordin g to grain of wood




1-22

Fi gu r e 1-15. P r o t ec t i on fo r ba r r i e r an d it em s u r face s .




1-23

P LYWOOD BLOCKING AND B RACING

Plywood is used to distribute the load when the face of an item is flat but

structurally weak and the weakness prevents that face from being used as a

bear ing area . By covering the face of th e item with a sh eet of plywood, so

tha t t he plywood bears on str onger portions of the face, the load of the item is

distributed uniformly against the container and injury to the weak face is

prevented. The edges of the p lywood sh eet a re pa dded with felt, if necessary,to prevent the plywood from marring the surface of the item (fig 1-15).

Plywood can be used for making pressure strips to distribute the load of an

item on th e gaskets when a floating water-vaporpr oof barr ier is used. This

meth od, which minimized th e possibility of barrier da mage du ring sh ipment,

is illust ra ted in figure 1-15. When it is not pra ctical to block an ir regu lar

item to transfer the load evenly to all faces of the container, it is wise to

secur e the item to a solid base which ma y in tu rn be blocked to evenly

distr ibute th e load. If th e conta iner is of fiberboar d, plywood serves as a good

pallet to which the item ma y be bolted or stra pped. The plywood, in tur n, is

securely blocked int o th e conta iner by a holddown or top pad . Thin plywood

is used to advantage where the blocking must be flexible to conform to a

cur ved su rface.

Plywood is used where th in mat erial is required as a br ace in ten sion. When

an item is to be bolted to a base or auxiliary base, plywood is used for the

base because of its resist an ce to splitting (fig 1-16). Since plywood is

obtaina ble in wide pa nels, it is especially useful in base constr uction. For

light item s, 1/2-or 3/4-inch plywood should be used. For mediu m an d hea vy

items, two or more pieces of plywood can be fastened together, or a series of

stren gthening cleats can be added to th e panel. The cleats also may be of

plywood to redu ce the possibility of splitt ing.

C OMBINED P LYWOOD AND L UMBER BLOCKING AND B RACING

Plywood and lumber, combined into a blocking and bracing assembly, unite

the advantages of a strong, lightweight sheet material with a material that is

easily cut an d na iled. Plywood is used a s a sh eet with wooden blocks nailed

to the sheet. The nu mber, dimensions, and p lacement of the wooden blocks

depend u pon th e sha pe of the item, its depth , the position of an y projections,

and th e loads to be supported at th e various bearing area s. The required

thickness of the plywood depends upon the span between the blocks and the

load to be distr ibuted . The sheet of plywood mu st be stiff enough t o resist

bending so as to evenly distribute th e weight of the item . Position the blocks

upon the plywood sheet at places where the item can withstand concentrated

loads. Wherever possible, locate the blocks and braces against the stronger

portions of the item. Choose nails that are long enough to permit clinching

after being driven thr ough the wooden blocks and th e plywood sheets. If

clinching is impr actical, drive the na ils th rough t he t hinn er piece first. Cover

all surfaces of wood blocks contacting the item with felt and glue in place.Where the felt-covered blocks normally contact critical surfaces of the item,

use greaseproof or water-vaporproof barrier material between the felt and

the item. Eliminate time consu ming constru ction of a framework at th e time

of packing by us ing prefabr icat ed blocking.




1-24

Figur e 1-16. Uses of plywood for blocking an d br acing.

NAILS AND NAILING

Nails shall conform to the requirements of ASTM F 1667-95. All nails that

are not clinched shall be cement coated, etched or mechanically deformed

(helically or annu larly thread ed). Unclinched nails shall be as long as

practicable without splitting the material, but not shorter than three times

the thickness of the member holding the nailhead for tenpenny nails and

smaller, or not shorter than the thickness of the same member plus 1 1/2

inches for twelvepenny nails and larger. Nails loaded tr an sversely to their

length (later al) in blocking and bra cing joints need not be clinched. En d




1-25

grain nailing in solid wood or edge nailing in plywood shall not be permitted.

Nails shall be driven through the thinner member into the thicker member

wherever possible. Nails shall not be subject to withdra wal stresses. Nails

shall be driven not closer to th e end of a piece of lumber t ha n t he t hickness of

the piece and not closer to its side than one-ha lf its thickness. There sh all be

at least t wo na ils in each joint. Lat era l loading of na ils for blocking and

bra cing sha ll be in accorda nce with t able 1-4. En ds of blocks and bra ces sha llnot be fasten ed to a wood conta iner by end-grain na iling met hods. Blocking

and bracing shall be applied against areas of item(s) that are of sufficient

stren gth a nd r igidity to resist dama ge. A description of the various types of

nails and general requirements for their use are given in chapter 3.

Standard sinker and cooler nails are particularly well suited for use in

blocking and bracing and should be coated or chemically etched etched

especially if th e nails can not be clinched. If na ils fail when s ubjected to

forces of direct withdrawal, apply nails so that they are subjected to forces of

lateral displacement rather than direct withdrawal, that is, the direction of

the n ails is perpend icular to the direction of the load, rath er th an in line with

the direction of the load.

B OLTS AND BOLTING

Carriage or step bolts shall be used as fastenings for wood or plywood

blocking and bracing where necessary to facilitate disassembly for removal of

cont aine r conten ts. Bolts sha ll also be used for fast enin g blocking an d

bracing members th at ar e too thick for proper fastening with nails. Bolt

holes in wood or plywood sha ll be of th e same dia met er as t he bolts. Bolts

commonly used for blocking and bracing are machine bolts, carriage bolts,

and step bolts.

Step bolts are preferred for th is use because of th eir larger head diam eter. J -

or U-bolts are used for special conditions where regular bolts cannot be

app lied (fig 1-17). Tie rods and J -bolts ar e actua lly exten ded bolts, applied in

pairs either vertically (fig 1-18) or diagonally (fig 1-19), and are used where

stan dar d length bolts would not apply. See table 1-5 for the suggested

allowable load for th e various sizes of bolts. The following pr ecaut ions sh ould

be observed in th e use of bolts:

Items su ch as ma chines or su bassemblies having bolt h oles in part s which a re

stur dy enough to resist break age when rough h and ling should, if pra ctical, be

bolted t o one face of th e conta iner . If nonprecision bolt holes ar e involved,

the diameter of the bolt should be the nearest standard size consistent with

the diam eter of the h ole.

Table 1-4. Allowable later al loads for unclinched cemen t-coat ed or etched comm on wire nails

when used for blocking or bra cing.

Spe cies of wood Load, pounds per na il

4d 6d 8d 10d 12d 16d 20d 30d 40d

White pine, ponder osa pine, spruce and

other group I woods

14 17 21 25 26 29 38 42 48

Souther n yellow pine, Douglas fir,

western larch, an d other group II woods

21 26 32 39 40 45 58 65 73

Oak, ma ple, birch, beech, ash , and oth er

group III an d IV woods

26 32 40 48 49 55 71 80 90




1-26

Figur e 1-17 Bolts for blocking and bra cing.

Figur e 1-18. Vertical use of tie rods.




1-27

Figur e 1-19. Diagonal use of tie rods.

Table 1-5. Suggest ed allowable lat era l loads for bolts-impa ct loading

Diameter of bolt (inch ) Allowable load

(pounds)

3/8............................... 35

1/2............................... 90

5/8............................... 150

3/4............................... 200




1-28

If precision bolt holes are involved, precautions should be taken to insure

that precision fitting bolts of the proper fit and characteristics are used to

prevent m ar ring or elongation.

Lag bolts should not be used for blocking and bracing.

Holes bored through containers or mounting bases must be the same size asthe diam eter of the bolts to be used. When mount ing items to cont ainer bases

equipped with skids, extend the bolts through the skids, whenever practical,

and in such insta nces counter sink th e bolt in th e outer sur face of the ru bbing

strip. Use standard cut washers under the nuts to decrease the possibility of

the bolt pulling through th e wood. Make sur e tha t th e nut s do not come loose

intransit by turning the nut securely on the bolt, and either upsetting or

nicking the t hrea ds of th e bolt beyond th e nu t; applying asph altum , paint, or

lacquer on t he t hr eads; using lock nut s; or u sing cotter pins with the nu ts; or

lock washer s. Metal plates or flat washer s are used between lock washers

and wood to pr event direct conta ct.

Bolts and nuts that are not corrosion-resistant must be completely covered

with corr osion preventa tive compounds. The compoun d must be thoroughlyset before th e bolts a re u sed.

Where the item has strong frame members fairly close to the face of the

conta iner, consider u sing U- or J -bolts. Whenever feasible, the n ut end of the

U- or J-bolt should be on th e out side of th e conta iner . In su ch cases, it is

especially important to upset the threads or otherwise prevent the nuts from

loosening.

Use tie rods as extended bolts to secure items when J- or U-bolts are

un suitable. Place tie rods in pairs, either diagonally or vert ically as may be

necessary. Attach the tie rods to a reinforced point of the cont ainer a nd u se

them with washer s bearing against the wood. Be sur e the tie rods pass

through the base at an angle which will not cause bending or kinking of the

rod. Any kinking will weaken t he r ods and increase t he possibility of failure.

ANCHORING

Anchoring of heavy items should be accomplished by securing the item to a

base by tension devices, either by bolts through mounting bolt holes on the

item (bolting down); or by metal strapping, cables, tie rods, chains, wire, or

other tension devices attached to, or applied over, the item (tiedown or

holddown); or by both. The sam e washe r requ irem ent a s specified for bolts of

equal diameter should apply to tie rods.

ANCHOR BOLTS

Carr iage or step bolts should be used. Articles having moun ting holes in

areas that can withstand rough handling without breakage shall be bolted toeither th e base of th e container or an a uxiliar y base. The bolt heads of

anchor bolts (those holding the item to the container base or the auxiliary

base) should be on t he outside of the cont ainer, other wise on t he u nder side of

the au xiliary base. The heads of all an chor bolts sha ll bear against a wide

washer conforming to FF-W-92, type A or B, grade I, class A, medium size,

except that the minimum diameter or minimum size of square bolts shall be

as specified in table 1-6 when th e member adjacent to th e bolt hea d is wood.

Bolts th rough m ounting bolt holes sha ll form a snu g fit, except t ha t p recision

holes shall be bushed to prevent dam age by an chor bolts. In a crate wher e

the item is bolted to a skid-type base, the an chor bolts shall pass th rough th e




1-29

skids or th rough loadbear ing members that a re bolted to th e skids. Bolt

holes in wood should be of th e same diameter as th e bolts. The ma ximum

allowable load for anchor bolts required and the minimum size of wood-

bearing washer s should be as specified in t able 1-6. When t he weight of th e

item exceeds that shown which can be anchored adequately using allowable

loads in table 1-6 and a ll of the a vailable mount ing bolt holes on t he item, the

excess weight shall be taken care of by tiedown provisions specified herein.After the nuts have been tightened, the exposed bolt thread should be

painted with aspha lt unless locknuts or cotter pins are used. The required

size and quantity of bolts used as tie rods or for anchoring the ends of the

tiedown ten sion member s should be in accordan ce with ta ble 1-6. Lag bolts

should not be used in lieu of carriage or step bolts.

METAL BRACKETS OR F RAMES

Many items have attachment points which provide facilities for bolting, but

often these points are not located on the base, so that brackets must be used

to fasten th e item to the container. In th ose situat ions wher e tie rods or U- or

J-bolts cannot be used, specially constructed brackets, sleeves, or frames

made entirely of metal, wood, or a combination of these, are used to act as

interm ediate connections between the item and the conta iner. These fram esor brackets mu st be designed with sufficient str ength an d fastening facilities

to hold the item to the conta iner securely. Select sleeves tha t will fit th e

interior of the container sn ugly and will ha ve sufficient str uctur al stren gth t o

sup port th e load (fig 1-20).

Table 1-6. Maximu m allowable loads and min imum sizes of wood-bearin g was her s for anchor or

tiedown bolts.

Diameter of

bolt

Wood-bearing washers Maximum allowable load per bolt

Minimum

diameter of

round

Minimum size

of squa re

Items weighing

200 pounds and

less

Items weighing

200 to 3,000

pounds

Items weighing

over 3,000

pounds

Inch Inch Inch Pounds Pounds Pounds

1/4 1.35 1.00 10 --------------- ---------------

5/16 1.75 1.25 30 --------------- ---------------

3/8 2.10 1.50 50 75 ---------------

2 2.85 2.10 100 150 300

5/8 3.60 2.65 150 225 450

3/4 4.70 3.25 --------------- 375 750




1-30

Figure 1-20. Use of meta l brackets, fra mes, and sleeves.

METAL ST R A P P I N G

Metal strapping used to tie down an item to the base or other face of the

container or to an auxiliary base should be flat steel strapping material

conforming to ASTM D 3953 and ASTM D 4675. Tiedown stra pping sh all be

securely att ached t o fig 1-20 or looped over th e item. It sh all be an chored to

the container or auxiliary base either by looping around a load bearing

member or by utilizing steel slotted anchor plates for flat strapping secured

to the conta iner or auxiliary base. Pad ding material or suitable edge

protectors, as applicable, sha ll be used under th e stra ps to prevent da mage to

the item. Whenever possible, all stran ds holding down an item sha ll be of




1-31

appr oximately the same length . Maximum allowable loads for each st ran d of

tiedown str apping sha ll be in accordance with ASTM D 4675. Ea ch t iedown

stra p passed over an item should be considered as one stra nd. All tiedown

stra pping sha ll be tensioned an d sealed or tied secur ely.

ST R A P P I N G P RECAUTIONS

Metal strapping may be the only convenient way in which an item orcont ain er can be secured or reinforced (fig 1-21). Meta l stra pping ma y be flat

steel mat erial. Stra pping is tensioned an d prefera bly sealed with specially

designed tools. If th is is not possible, flat st ra pping can be held in pla ce with

anchor plates. Genera l precautions on the use of meta l stra pping which

app lies to flat s teel a re a s follows-

Where possible, the item an d its supp ort mu st be completely encircled. When

it is impossible to do this, anchor the two ends of the metal strapping as

follows:

• For flat strapping, anchor the two ends of the strap to the container

base with anchor plates, or if the strap is designed for nailing, nail

the ends of th e strap to the container base. Place the n ails so th at th estra ps exert a pull at right angles to th e nail axis. For round wire,

anchor the two ends of the round wire to the container with

drivescrews and staples. Loop the wire around the sha nk of the

drivescrew and furth er anchor the wire by mean s of staples. Be sure

the wood is thick enough to hold the entire length of the drivescrew

an d tha t th e drivescrew is of adequa te gauge to car ry the load. When

drivescrews are used, place them so that the wire exerts a pull right

an gles to th e drivescrews axis. Apply tension to the stra p with a

tension tool an d seal the str ap in the cust omary mann er. Use a one-

piece stra p wherever possible. Stra ps should be placed only on those

strong portions of the item which can withstand the impact load and

weight of the item. Where strapping passes over a sharp edge of the

item, use corner protectors, if necessary, to prevent the strapping

from becoming fractured.

• Protective materials should be used between the item and the strap if

the str ap is likely to scratch or otherwise injure the item. Arran ge

strapping on the container, where possible, to further reinforce

blocking and bracing or anchoring of the item within the container.

Use an nealed str apping only for lighter items, since it str etches more

readily than the more highly tempered tension strapping.

M INIMUM LENGTHS OF STRAPS

The minimum total length of straps shown in table 1-7 does not include that

portion of material used to make a secure fastening at the ends of each

stra nd but is the sum of, an d does include, all lengths of ma terial betweensuch fasten ings. Overall lengths of each stran d shall be adequa te to permit

fasten ing as sp ecified above.

MAXIMUM ALLOWABLE LOADS

The maximum allowable loads are based on available energy of 8,640 inch-

pounds per cubic inch of strap in tension and an assumed drop height of 30

inches, as established by ASTM D 3953. If grea ter loads ar e to be tied down

or if other sizes of strap a re u sed, additional st rap ping shall be applied on t he

basis of 300 poun ds of load per cubic inch of str ap in ten sion.




1-32

Figure 1-21. Use of meta l strapping for bra cing and a nchoring.




1-33

Table 1-7. Tape strips used in han dling rigid mat erials1

Type III tape band width in inches (minimum )

Gross weight of bundle Number of encirclements (Example: Thr ee encirclements could refer to ei ther three

separa tely located single wrapped ba nds or t o one ba nd which completely overlaps itself three

times)

Pounds

Up to 20 incl...............

Over 20 to 40 incl..........

Over 40 to 60 incl..........

Over 60 to 80 incl..........

Over 80 to 100

incl.........

Over 100 to 150

incl.......

Over 150 to 200

incl.......

Over 200 to 300

incl.......

Over 300 to 400

incl.......

Over 400 to 500

incl.......

1

3/4

1

1 1/4

1 1/2

........

......

.......

.......

.......

.......

2

1/2

3/4

1

1 1/4

1 1/2

........

........

........

........

........

3

1/2

1/2

3/4

1

1 1/4

1 1/2

........

........

........

........

4

1/2

1/2

1/2

3/4

1

1 1/4

1 1/2

........

........

........

5

1/2

1/2

1/2

3/4

3/4

1

1 1/4

1 1/2

........

........

6

1/2

1/2

1/2

1/2

3/4

3/4

1

1 1/4

1 1/2

........

7

1/2

1/2

1/2

1/2

3/4

3/4

3/4

1

1 1/4

........

8

1/2

1/2

1/2

1/2

3/4

3/4

3/4

3/4

1

1 1/2

9

1/2

1/2

1/2

1/2

3/4

3/4

3/4

3/4

1

1 1/4

10

1/2

1/2

1/2

1/2

3/4

3/4

3/4

3/4

1

1

1 If mater ial to be bonded is somewha t flexible, tape width s ma y be redu ced by 25 to 50 percent.

In n o case sh ould less th an 1/2 inch tape be u sed.

STRAP P ING REINFORCEMENT FOR CONTAINERS.

ST R A P P I N G R E I N F O R C E M E N T F O R C ONTAINERS

In additions to the use of metal strapping as reinforcement for blocking or

bracing, its widest use is for reinforcement of exterior wooden containers.

Only tempered high tensile strength, flat steel strapping should be used as

wood container reinforcement, except in limited instances such as reinforcing

of a crate corner where annealed nail-on-type flat steel strapping is

employed. For export shipments, bare meta l stra pping should not be used

due to its lack of corr osion resista nce. Ea ch militar y an d commer cial

container specification has a section or an appendix devoted to closure and

stra pping. It is import ant tha t the instr uction contained in these

publications be observed.

WE B ST R A P P I N G

The use of web strapping to tie down an item to a base, to other faces of the

cont ain ers, or to built up fram e, is NOT considered a good pra ctice. Web

strapping has a tendency to shrink or stretch with change in moisture

cont ent , th ereby losing its ability to hold the item firm ly in place. It is

hygroscopic, and may cause corrosion to contacting metal surfaces, and it isoften difficult to an chor pr operly.

R E I N F O R C E D TAP E S F O R P ACKING

Various kinds of tapes have been developed with longitudinal filament

reinforcing stra nds to provide high tensile stren gth. When such tapes are

properly applied to containers or bundled items, significant increases in

resistan ce to rough han dling are att ained. These tapes consist of either a

paper or plastic backing, which ha s been coated on one side with an insoluble

pressure-sensitive adhesive, or a gummed adhesive that is activated by a

solvent . The high tensile strength of th e tape is produced by filamen ts of




1-34

nylon, rayon, glass, or otherfibers that have been lineally aligned and

embedded in the backing mat erial. When th e tape is applied to the cont ainer

so that the direction of the rough handling stresses are parallel to the

embedded filaments of the tape, considerable container strengthening

results. Longitudina l tensile strength of these ta pes may be over 500 pounds

per inch of width. Some of th e advant ages claimed for their use are th at

sufficient tensile strength and elastic properties are present to enable apackage or pack to be highly resistant to shock loads. The a dhesive holds th e

tape to the area of application and thus prevents slippage during handling.

These tapes do not easily snag and do not interfere with stacking and

han dling of conta iners. No special equipment is needed for t heir a pplication.

They provide a means of reducing pilferage.

R E I N F O R C E D P A P E R , GUMMED TAPE A-A-1492, A-A-1671

There ar e thr ee types and two classes available. Type I (reinforced, asphaltic

laminat ed) and Type II (reinforced, nona spha ltic laminat ed) are int ended for

use in so called single strip closure un der th e Un iform F reight Classification

Rule 41, section 7. Types I an d II ar e used for closure of fiberboar d boxes for

domestic shipment an d storage and for securing wrap pers of packages. Type

II sha ll be used wh ere th e presence of asph alt would ha ve a deleterious effecton the cont ents, such as food products. Type III is inten ded for u se in general

sealing of cart ons, fiberboar d boxes, and wr appers an d for ban ding paper an d

paper pr oducts. Class 1 (strippable) is used when ease of opening and

removal of the tape is desired. Class 2 (non-strippable) is used when removal

of the tape from boxes is not necessary for reuse.

F ILAMENT R E I N F O R C E D, P R E S S U R E TAP E ASTM D 5330

These tapes ar e supplied in four types based on tensile strength . Type I (low

tensile strength) has a minimum tensile strength of 160 pounds per inch of

width. Type II (medium ten sile strength) has a minimum t ensile stren gth of

240 pounds per inch of width for Class A, and 300 pounds per inch of width

for Class B. Type III (high tensile strength ) ha s a minimu m ten sile strength

of 425 poun ds per inch of width. Type IV (high t ensile strength, weat her-

resistant) has a minimum tensile strength of 400 pounds per inch of width.

Only Type II has two classes, based on the t ra nspa rency of the tape. Class A

is opaque or nontransparent, and Class B is transparent enough to allow

reading of printed ma tter th rough one layer of th e tap e. These tapes are

intended for use in securing packages and reinforcing bundles and

containers.

R E I N F O R C E D TAP E APPLICATION GUIDELINES

Individual container specifications, and appropriate standards should be

checked for th e proper use of reinforced tapes. Some basic ru les that may be

helpful a re a s follows:

• Do not use a wide tape if a narrower tape is strong enough to

accomplish t he int ended pu rpose.

• If it is anticipated that high humidity conditions or excessive

moisture will be encountered in shipment or storage, use tapes with

water insoluble adh esives.

The adhesion of tapes to the surface of a container will depend upon the

condition of the su rface. Hence, in st rip applicat ions, th e strips should be

long enough to provide sufficient adhesion to take advantage of the full

potential strength of th e tape. This should require at least 6 or more inches




1-35

of good contact between the ta pe and t he cont ainer su rface. The ta pe length

should be equ ally divided over a s eam , scoreline, or oth er point of application.

In using reinforced paper gummed tape (A-A-1492, A-A-1671) for sealing

containers shipped under the jurisdiction of the Interstate Commerce

Commission, only th e cent er seam of a cont ain er needs to be sealed. This is

accomplished by using a strip at least 3 inches wide which must extend no

less than 2 1/2 inches over ea ch end of the cont ainer.

In using filament reinforced, pressure-sensitive tape ASTM D 5330, the

following inform at ion will serve as a guide in its u se. It sh ould be recognized

that special conditions will necessitate occasional deviations from these

recommen dat ions in the inter est of economy or good pra ctice. The filamen t

reinforced, pressure sensitive tapes are intended for use in reinforcing

fiberboard or fiberboard surfaced containers, strapping, bundling, and other

miscellan eous applications. Type I, char acter ized by high elongat ion an d low

tensile strength, is best suited for strip reinforcement of containers and

anchoring moving parts. Type II with lower elongat ion but h igh tensile

stren gth, is also suited for closures. Type III, with higher ten sile strength

and low elongation, is most effectively used in complete wraparounds such as

bundling an d other forms of circumferential binding. Type IV should be usedwhere weather resistance is required and should be used in the same length

as the type it replaces. These tapes should be applied in cont inuous strips.

Typical application are shown in figure 1-22. Tape should be smooth ly an d

firmly adhered to surfaces which are relatively smooth and nominally free

from du st, dirt, grea se, and moistur e. Care sh ould be taken to avoid excessive

handling of tape adhesive surfaces, particularly at the ends of the strips.

Such excessive handling might contaminate the surface of the adhesive and

redu ce its a bility to bond firmly.

The high t ensile strength tap es are also used for bu ndling of rods, shafts, or

tubu lar objects for ea sier han dling. Table 1-7 shows the correct a mount s of

Type III ASTM D 5330 tape for u se in bundling. The ta pe should be applied

with sufficient hand tension to "snug" the bundle and secure maximum

contact between the ta pe and th e bundled items.

CUSHIONING

C USHIONING DE F I N E D

Cushioning is the protection given to items against physical and mechanical

dama ge by means of appropriate ma terials which absorb the en ergy of shocks

and vibrations through a gradual but increasing resistance to the movement

of the item. The energy from shocks and impa ct is absorbed when th e

cushioning material is compressed, which in turn increases the pressure

upon the entrapped air within the cushioning material, resulting in a

damping or minimizing of the force to the item.

C USHIONING VE R S U S BLOCKING AND B RACING

The distinction between cushioning and blocking and bracing is that

cushioning permits controlled movement of the item within the container,

while blocking an d bra cing usu ally are designed to prevent movement of the

item within the cont ainer.




1-36

Figur e 1-22. Use of filam ent r einforced tape.

C USHIONIN G AND C ORROSION

Where applicable, cushioning should be used in one or more of the followingways to provide necessary physical protection. Cushioning mat erials shall be

separated from surfaces which might be corroded at points of contact by

either noncorrosive wra pping pa per conform ing to Specificat ion MIL-P-130 or

grea sepr oof barr ier ma ter ial conforming t o Specification MIL-B-121, grad e A.

If a noncorrosive cushioning material is used, the wrap is not required.

Cushioning materials containing asphalt shall not be permitted to come in

direct conta ct with highly finished, varn ished, or lacquered sur faces.

F LOTATION OR SU S P E N S I O N




1-37

Delicate or fragile items should be protected against shock and vibration by

flotation or suspension within the shipping container by suitable cushioning

mat erials. These mat erials may be in sheet form a pplied to give support at

top, bottom, sides, and ends of the item. For items in stu rdy cabinets, cases,

consoles, or packed in an inner box, the cushioning material may be in the

form of prefabricated corner pads. Materials shall be bound fiber conforming

to PPP-C-1120; fiberboard conforming to ASTM D 4727; cellulosic materialconforming to A-A-1898; expanded polystyrene conforming to PPP-C-850;

prefoamed polyurethane conforming to MIL-P-26514; foam-in-place materials

complying with MIL-F-83671; or such other materials as specified in the

procurement documents.

ABRASION P ROTECTION

Protection against abrasion should be provided for highly finished or easily

mar red surfaces by wrap ping or covering with cushioning mat erial.

Surfaces damaged by contact with cushioning material should be separated

by a covering of noncorrosive paper conforming to MIL-P-130 or MIL -

P-17667 or gr easep roof bar rier m at eria l conform ing to MIL-B-121, Grad e A.

C OATINGS AND BARRIERS

Protection should be provided for strippable compound coatings and for

greaseproof, waterproof, or water vaporproof barriers at points of contact

with blocking, bra cing or projecting member s of cont ain ers. Cush ionin g

materials should be applied to reduce the static pressure at points of contact

of 30 pounds or less per squar e inch.

MOISTURE R ESISTANCE

Unless otherwise specified in the product specification, cushioning material

conforming t o A-A-1898 should be of th e wat er r esista nt type.

DUSTING

Cushioning materials that are not dust producing should be used for packing

items that are adversely affected by dust, unless a dustproof barrier is used

to prevent dust from reaching the item.

F ACTORS INFLUENCE CUSHIONING SELECTION AND USE

Shock resulting from rough handling or dropping of a shipping container is

the usu al cau se of mechan ical damage to th e contents. The purpose of

package or item cushioning is to reduce the intensity of the shock reaching

the pa cked item to a level which th e item can with stan d. Fa ctors influen cing

cush ion design a re t he fragility an d weight of the item, th e load-bearing ar ea

of the cushion, the dynamic, force deformation characteristics of the

cush ioning m ater ial, and t he equivalent height of drop (usually 30 inches) for

which pr otection is desired. Among th ese, the fragility an d weight of the item

are fixed values for any par ticular item. The load-bearing ar ea of the cush ioncan be altered by suitable blocking or by packing the item in an inner

container, if desired.

C O N C E P T O F C USHIONING

Cushioning is the protection from physical a nd mechanical dam age afforded

an item by means of compressible and resilient materials, known as

cush ioning m ater ials, designed t o absorb t he en ergy of shocks a nd vibra tion

caused by exter na l forces. Deta ils on "Pa ckage Cushioning Design" ma y be

obtained in MIL-HDBK-304.




1-38

F UNCTIONS OF CUSHIONING

In order to properly utilize the many cushioning materials available in the

military supply system, it is necessary to understand the functions of

cushioning. Among th ese fun ctions (fig 1-23) th e more import an t ar e--

• Controls movement and prevents damage caused by vibration.

Cushioning, when properly applied, controls the movement of theitem within the barrier or container and dampens vibration.

• Pr otect fragile or delicat e componen ts. When fragile or delicat e

components form a part of an otherwise rugged item, they may be

disassembled an d packaged separa tely. If disassembly is not

permitt ed an d t hey mu st be left in place, cush ioning is ap plied to give

them protection.

• Prevent ruptu re of barriers and containers. Many items have sharp

corn ers or projections wh ich could pu nctur e th e barr iers or conta iners

in which they are packaged, resulting in the entry of moisture or

water . Cushioning is applied to these projections or corn ers to insur e

tha t wat erproof or water-vaporpr oof barr iers are n ot rendered u seless

by such da mage.

• Distribute forces. Cushioning mater ials reduce the shock to an itemby distributing forces over a large area, thus lowering the stress

concentra tion a t a ny one point on the surface of the item.

• Prevent a brasion. Items with h ighly finished surfaces which ma y be

marred by blocking, strapping, contact with container surfaces, or

contact with other items in the container, must be protected against

abra sion by cushioning. Usua lly, lesser amoun ts and th ickness of

cushioning materials are employed to accomplish this cushioning

function.

• Absorb shocks. Perh aps the most frequent and importan t use of

cushioning is to absorb the energy resulting when an impact shock

strikes a cont ainer. This shock energy is absorbed as th e cush ioning

mat erial is compressed by the impact.

MULTIPURPOSE CUSHIONING

The foregoing functions of cushioning should not be considered separately

because cushioning is often used for more than one purpose in the same

package. Material selected to protect an item against shock may at t he same

time minimize movement, prevent a brasion, protect bar riers, and cover sha rp

projections. Man y cush ionin g mater ials also act as good insu lation to protect

items against dra stic temper at ure cha nges. Cushioning may be required to

absorb liquids and consequently must have liquid-absorbing qualities to

prevent liquid flow in case of breakage of the containers.

R E Q U I R E M E N TS F O R T H E USE OF C USHIONING MATERIALS

In addition to the requirements established in cushioning specifications inregard to material quality, construction, and performance, other important

requirements must be met when cushioning materials are used within

water proof or water-vaporpr oof barr iers. Sound packaging design pr actices

dictate placing only the minimal required amount of cushioning material

within water-vaporproof barriers, thereby minimizing the barrier area and

the desiccant r equirement s. in ad dition,




1-39

Figur e 1-23. Fu nctions of cushioning.

• Cushioning shall be as dr y as pr acticable.

• If the item is coated with a preservative, the preserved item must

first be wrapped in a barrier conforming to MIL-B-121, Grade A, QQ-

A-1876, or MIL-B-22191, Type I or II, before applying the cushioning

material .

C USHIONING SELECTION F ACTORS

There ar e several factors tha t mu st be considered in selecting th e appr opriate

cush ioning mater ial for a given application. The nat ur e and physical

limitations of the item, the favorable and unfavorable characteristics of the




1-40

cushioning material, the destination of the packages, and the means of

transportation must all be taken into consideration before an item can be

properly cushioned.

NATURE OF THE I TE M

In planning to cushion an item, the nature and physical limitations of the

item must first be considered. The shock resistan ce, size, weight, sha pe,surface finish, and the degree of disassembly permitted will influence the

way a n it em is to be cush ioned (fig 1-24).

SHOCK R ESISTANCE OR F RAGILITY

Fra gility may be observed, but cann ot be measu red accura tely by eye. The

tendency is to overcushion seemingly fragile items and to undercushion

seemingly stur dy items. Fra gility-the grea test am ount of dynam ic force an

item can withstand without destruction--can be measured with scientific

instru ment s. The term "G-factor" has been a ccepted as indicating the shock

resistan ce of an item. This resistance is determined by measu ring the peak

acceleration (deceleration) an item will withsta nd dur ing impact a nd dividing

this acceleration value by the acceleration due to gravity (32.16ft/sec/sec).

This is expressed as--

G-factor = Acceleration of the Item

Accelerat ion due t o Gravity

The G-factor values of man y milita ry items are being determ ined. In th e

absence of known G-factor values, the selection of cushioning must be based

on experience with previous shipments and testing of similar items, or by

assum ing a G-factor for d rop test pur poses.

Figure 1-24. Item char acteristics determin es the selection

of cush ioning mat erials.




1-41

S IZE

A large item m ay require a thin ner layer of cushioning th an a sm aller item of

the same weight because there is less load per square inch applied to the

cushioning. This should be kept in mind when an item is irregular in shape-

more cushioning may be required at th e small end than at the large end.

WE I G H TWeight in motion resu lts in force, and force can cau se dama ge. Thus, th e

weight of an item controls the thickness, quantity, and firmness of the

cush ioning mat erial to be used. Genera lly, the hea vier th e item, the firm er

the cushioning must be.

SHAPE

A regular-shaped item will ordinarily fit snugly into a container with a

minimum of cushioning, while an irregular-shaped one may require a

complicated arrangement of pads and cells or foamed-in-place cushioning to

bring it to a more regular sha pe. Light , small items which are irregular in

shape can be made regular an d at the sam e time positioned an d held in th e

container mer ely by a wra p of cush ioning mat erial. Large, irregular item s

may make it impractical to use cushioning materials to make them regular.Blocking and bracing will have to be employed to adequately protect such

items.

SURFACE F INISH

An otherwise sturdy item may have highly finished surfaces which could be

damaged by the rubbing action of harsh abrasive cushioning material, or the

surfaces may be corr oded an d pitted by chemical action due t o the pr esence of

moistur e an d acidic or basic element s in th e cushioning ma terial.

C HARACTERISTICS OF CUSHIONING MATERIALS

The chemical and physical properties of cushioning materials are many and

may display both desirable and undesirable characteristics. These

cha ra cteristics vary in importan ce for different applications. What might be a

highly desirable characteristic in one application, may be detrimental in

an oth er. For instan ce, high moisture absorbency is required for packaging

liquids, but is not desira ble when packaging corrodible met al items.

Compression set (fig 1-25) is the difference between the original thickness of

a cushioning material and the thickness of the same material after having

been released from compression under a standard load for a given period of

time. This is importa nt in determ ining whether a cushioned item can rem ain

in storage for an extended period of time without causing the cushioning to

lose its resiliency. Perm anen t compression set is undesirable when it creates

free-moving space in the container.

Resilience (fig 1-25) is the ability of a material to absorb a series of shocks

and retu rn to its original sha pe an d thickness after each shock. Few

materials are completely resilient and this quality is often greatly altered by

cha nges in tempera tu re. Rubber, for instan ce, is highly resilient in

temperate zones, but loses its resilience under extreme climatic conditions.

Rate of recovery (fig 1-25), or the time it takes for a cushioning material to

return to its original shape after compression, is also important as some

mat erials ha ve too rapid a rat e of recovery and "spring back" so quickly tha t

damage to the item may r esult .




1-42

Figur e 1-25. Cha ra cteristics of cushioning compress ion set,

resilience, and rate of recovery.

Dusting, which results from the breakdown and disintegration of certain

mat erials used for cushioning, allows sma ll part icles to become detached an d

work into crevices and critical working surfaces of the cushioned item (fig

1-26).

The corrosive effect of some cushioning materials is undesirable when

packaging items with critical surfaces. When th is cann ot be avoided, the

item must be shielded from such materials by a neutral wrap or liner.

Cushioning mat erials with a high a cidic or basic content mu st n ot be enclosed

with in water proof or wat er-vaporpr oof bar rier s (fig 1-26). When cushionin g

material contains natural hair, it shall be treated with insecticide to prevent

carp et beetle infestation.




1-43

Fu ngus resistan ce of some m ater ials is low an d a llows for the growth of mold,

mildew, and other fungi. Many mat erials can be treat ed to inhibit such

growth. However., such tr eated ma terials are often very corrosive to metal

surfaces and must be isolated from them (fig 1-26).

The abrasive characteristics of some materials are factors which must be

considered when protecting precision surfaces such as the lenses of opticalinstru ment s. Some cushioning mater ial ar e soft-textured an d genera lly can

be placed in contact with easily marred sur faces. Coarse textu red ma terials

should n ot be used on su ch sur faces (fig 1-27).

Figur e 1-26 Cha ra cteristics of cushioning dust iness, corrosiveness,

and fungus resistance.




1-44

Low temperature performance of certain cushioning materials makes them

suitable for use in high altitude transport and in shipments to cold regions

because they remain relatively soft and resilient (fig 1-27).

Other characteristics which should not be neglected in choosing cushioning

materials are fire resistance or flammability (fig 1-27), and the possibility of

the mat erials cau sing skin irrita tion t o personn el who come in contact with it.

Des t i na t i on o f t h e I t em

The destinat ion of the item is a factor in cushioning. Many cushioning

materials change their characteristics under extreme climatic conditions.

Some mater ials become so rigid or brittle at extremely low temp erat ur es as t o

mak e them useless as cushioning mater ials. In tropical climat es, some

mat erials soften an d lose their cushioning qualities. In jungles or rainy

locations, some materials will pick up excessive moisture which will result in

the loss of resilience and will lead to growth of fungus and accelerated

corrosion.

M e a n s o f t r a n s p o r t a t i o n . The means of transportation must not be

overlooked. Haza rds a nd h and ling situa tions var y greatly between air, motor,rail, and ship. For example, there ma y be considerable difference between

the amount of handling that an item being transshipped from truck, to rail,

to ship would get and one th at is being shipped by air freight. Likewise, an

item to be delivered by air drop would require different protection from one

tha t would be delivered by tru ck.

R EPRESENTATIVE C USHIONING MATERIALS

Cus h i on i ng M a t e r i a l , Uncom p r es s ed Bou nd F i be r ( PP P -C-1120)

This material may consist of any suitable natural hair, vegetable fiber, or

synthet ic fiber bound with an elastic mat erial. Horsehair, sisal, an d cactus

fibers sprayed with lat ex are examples. It is fur nished in five types an d two

classes a nd th ree gra des. Type I is soft, Type II is medium soft, Type III is

mediu m firm, Type IV is firm, an d Type V is extra firm . When s pecified, each

type shall be identified with a color matching as closely as possible to colors

shown in Fed era l Stan dar d 595, as follows: Type I, brown; Type II yellow;

Type III, ora nge; Type IV, red; and Type V, black. Class A is wat er-resist an t

and Class B, a commer cial class, is not necessarily water -resistan t. Gra de 1 is

a flame r esistant mat erial; Grade 2 pr ovides low temperat ur e chara cteristics;

and Grade 3 is a standar d material . This material may be supplied as

un compr essed sheets an d rolls an d in molded shapes t o fit th e contour s of the

item. The ma ter ials have a high degree of resilience, low compress ion set,

fair damping quality, and do not disintegra te easily. They are neutr al and

have a low water-soluble acidity so that their corrosive effects are slight.

Moisture content and moisture absorption are both low; however, themat erials may need to be treat ed for fun gus resistan ce. Their perform an ce is

good at low temper atu re. They ar e intended to protect items against

vibrational and impact shocks where resilient and water-resistant cushions

are required.




1-45

Figur e 1-27. Ch ar acter istics of cushioning abras iveness,

temperature performance and flammability.

Cel lu los ic Cu shion ing Mater ia l (A-A-1898)

This mat erial may be m ade of any kind of cellulosic matt er wh ich will result in a

product meeting specificat ion r equirement s. The cellulosic mat ter u sed may be

cotton, bonded fibers, na tur al fibers, or creped wadding. The mat erial isfur nished in two types--Type I, water a bsorbent , and Type II, water resistan t. It

is available in three classes-Class A, low tensile strength, Class B, high tensile

stren gth, and Class C, very high ten sile strength . Cellulosic cushioning mat erial

is readily moldable and fairly resilient. Its compression set is high, its damping

ability excellent, but dusting is great enough to require an excluding wrap

aroun d items susceptible to dust dama ge. Its performa nce in cold temperat ur e is

good. This m ater ial is intended for u se in packaging light weight , fragile items; as

a protection against abrasion; and Type I, specifically, for absorbing liquids from

containers broken in transit.




1-46

So li d And Cor r u ga t ed F i be r boa r d ( ASTM D 4727)

Both solid and corrugated fiberboard are used in cushioning, but corrugated is

more frequen tly used becau se it has great er cushioning value. The most common

forms of fiberboard applications are die-cuts, open end cells trays, pleated pads,

an d flat pa ds (fig 1-28). Gener ally, cells and tr ays should be held in shap e with

tape. Those surfaces of the cell or tra y which a re perp endicular to the conta cting

surface of the item ar e called bracing supp orts an d ar e load bear ing members. Toutilize all of the str ength of these br acing su pports, th ey should bear directly on

the item. Pleated pads ha ve greater r esistance to break down than open end cells

because the load is spread over a large area rather than bracing supports.

Therefore, they should be used to cushion heavier loads (up to 2 poun ds per

square inch). Flat pads are used to block shallow projections, to level off

projecting screw heads, and to separ ate items within a conta iner. They can be

slotted to form pa rtitions, or may be die-cut or pu nched t o fit ar ticles or irregular

shape. Application of fiberboard cells, trays, and pads is illustrated in figure 1-29.

Uni ce l lu l a r P o l yp r opy l ene F oam (P P P- C-1797)

This material is a low density, resilient, unicellular (closed cell) polypropylene

foam material for use in cushioning and packing applications in the form of rolls

or flat sheets. Type I electrostat ic discha rge is required. It is useful thr oughout atemperature range from minus 65°F to 160°F. It is intended for use as a

cush ioning wrap for low density items. The foam can be lamina ted to a wide

range of products including paper, paperboard, and may be used for the

protection for optical lenses, equipment with critical surfaces, electrical and

electronic equipment , glasswar e, ceram ics, and m agnetic tape r olls. When stored

in closed containers it produces no trapped volatiles which could cause fire or

explosions. Polypropylene, by its nat ur e, is un affected by most exposur es to

grease water a nd most acids, bases an d solvents. It conta ins no plasticizers,

solvents, or lubricants.




1-47

Figur e 1-28. Exa mples of fiberboar d tra ys, opened end cells, pad s,

an d die-cuts




1-48

Figur e 1-29. Applicat ion of fiberboard d ie-cuts, open en d cells,

trays, and pads.

E XPANDED P OLYSTYRENE (PPP-C-850)

This resilient cushioning material consists of expanded polymers or copolymers of

styrene for use in packaging applications. It is furn ished in two types. Type I is

in sheet form an d Type II is in roll form. Both types come in four classes a nd t wogra des. Class 1 is soft, class 2-medium , class 3-firm, class 4-extra firm . Grade SE

is self-extinguish ing. This cush ionin g ma ter ial is used with in packages to pr otect

items from damage due to shock, vibration, abrasion, and concentrated forces

dur ing handling and shipment . It is especially suited where a high degree of

energy absorption is required in a minimu m space and with a m inimum weight of

cushioning. It can also be used to provide tempera tu re insulation or when

cush ioning mat erial must per form at extrem ely low tempera tu re.




1-49

C USHIONING, WR A P P I N G P APERBOARD (A-A-1051)

This is a pa perboard composed of a corr ugated sheet or a solid m olded pu lp sheet

firmly cement ed to a backing flat sh eet of un bleached su lfate fiber pa per. The

paperboard is furnished in two types--light and heavy-duty, and in two styles.

Style 1 mater ial must h ave a backing sheet. The backing sheet is optional for

Style 2. It is fur nish ed in sheets or rolls, as desired. Both styles are flexible in all

directions. This mater ial ha s high compress ion, low resilience, excellentdamp ing, and some dust ing. The moistur e content an d moisture absorption are

high. The moisture is not neutr al and hen ce has a h igh corrosion effect. Its

performa nce in cold weath er is poor, an d it is neither fungus n or flame r esistant .

Critical meta l items m ust first be wra pped in a chemically neutr al or greaseproof

barrier.

R IGID OR F LEXIBLE P OLYURETHANE F OAM (MIL-PR F -26514)

This material consists of both rigid and elastic types of foamed products obtained

th rough th e proper blending of complex synt het ic chemical compoun ds. By

proper combinations, reaction mixtures can be poured or pumped into various

sha ped cavities. Volatilization of th e blowing agen t cau ses ra pidly stiffenin g

resin to expand, completely filling th e space. The ma terial th en sets r apidly to a

lightweight, cellular str uctur e that ha s excellent cushioning properties. Themat erial is furnished in a form suitable for foaming in-place application or it may

be performed a nd su pplied in rolls, sheets, or m olded sha pes. Strong rigid foams,

tough elastic foams, soft flexible foams, and spongy water absorbent foams can be

obtained by the different choices of ingredients. Foams with densities as low as

.5 poun ds per cubic foot may be obta ined. These foam s can be adjust ed to give a

high or low compression set, excellent or poor damping, and high or low

resilience. In oth er words, the material can be tailor made to meet the

requiremen t of any type of cushioning required. There is no dusting problem;

moistur e content is negligible. The ma terial is flame an d fungus-resistant , and it

performs well in cold climates. For fur ther details regarding procedures an d

equipment used with polyurethane foam, see MIL-HDBK-775 and MIL-F-87075

respectively.

LATEX F OAM SP O N G E R UBBERS

These materials are made by incorporating into the rubber an inflating agent

such as baking soda, that gives off a gas which expands the mass during the

vulcan ization process. The rubber is made from slab rubber into sheets, strips,

molded or special shapes. These mat erials may be supplied in cored or u ncored

types; soft, medium, firm, and extra firm, classes; and in flame resistant and

nonflame-resistant gra des. The mater ials ha ve a very high resilience, low

compression set, fair damping properties, high moisture content, and high

moistur e absorption. They produce some dusting. If kept dry, th e corrosive

effects are slight. Their low temper atu re performan ce is poor. The mater ials

have a high density an d are expensive to use. The molded forms are often u sed

in conjunction with reusable containers and the initial cost is reduced by theamoun t of reuse obtained.

P LASTIC F ILM , H E AT SEALABLE , F LEXIBLE , C ELLULAR (PPP-C-795)

This material is constructed of a composite of two or more sheets of plastic film,

one face having uniformly distributed closed cells (bubbles), the other a flat

sur face. It is ava ilable in th ree classes : class 1-regular ; class 2-ant ista tic, tint ed;

and class 3-fire ret ard ant . All are u sed as cushioning for packaging applications.

Material is furnished with various cell sizes (air bubbles). It is intended for u se

within packages to protect items from damage due to shock, vibration,

concentr at ed forces, corrosion, contamin ation, and abra sion dur ing ha ndling an d




1-50

shipment and is especially suitable for use as inserts within transparent bags.

The use of class 1 material, due to its transparency, permits inspection of the

contents without opening th e pack. The flexibility of the ma terial perm its it to be

used as pads, bags, wraps, dunn age, or as a filler. Class 2 mat erial protects

sensit ive electr onic devices from electr ostat ic dischar ge dam age. When fire-

reta rda ncy is required, class 3 m ater ial is selected.

Note: Many of the ma terials made und er this specification are laminat es of

chlorinated plastic and polyethylene. Chlorinated organic ma terials give off

vapors of hydrogen chloride which can combine with water to form highly

corrosive hydrochloric acid.

UNICELLULAR P OLYETHYLENE F LEXIBLE F OAM (PPP-C-1752)

This specification covers six types and four classes of cushioning material. Type

refers to the den sity range of th e mater ial. For example, type VII has a density of

.9 to 2.0 pounds per cubic foot while type V has a density range of 6.0 to 10.0 per

cubic foot. The class genera lly describes the form the m at erial tak es and ma y be

solid or lamina ted planks, sheets, cut sh apes, rounds, or molded shapes. In

addition, type VII, class 4, mat erials are ant istatic. Temperat ure performa nce

has a useful range of minus 65o to plus 165oF. Compr ession set is low an d themat erials are n oncorrosive, nona brasive, and virtu ally dust free.

OP E N CE LL P LASTIC C USHIONING (PPP-C-1842)

This material is made of one sheet of plastic film or a composite of two or more

sheet s of film, formed int o a net work of un iformly distribu ted open cells. The

cells may be a hexagonal or fluted shape, depending upon whether a facing or

reinforcing top film lamina te is required. The hexagonal form is u sed when a

rein forcing top lamin at e is applied to the open face of th e cells. The fluted form is

used wh en a facing is ap plied to th e crowns of th e formed cells. The resu lting

mat erial is light weight , tra nspa rent , flexible, an d heat sealable. There ar e three

types; Type I, hexagonal; Type II, fluted; and Type III, hexagonal, electrostatic

free. The two styles describe whether or not the ma terial has a t op laminat e or

facing. All three t ypes are available with or without a top lamina te or facing and

are furn ished in rolls or sheets. The ma terial is noncorr osive, nonabra sive, has

low compression set, a nd per forms well at low temperat ur es. The cushioning is

intended for use within packages as inserts within transparent bags, wraps,

dun na ge, an d filler.

METHODS O F CUSHIONING

Cush ionin g is genera lly accomplished by one of th e following met hods:

• Floated item. The item is floated in cushion mater ial and placed within a

un it container (fig 1-30). This is perhaps t he met hod most commonly

used for cushioning small, lightweight, fragile items against shock,

vibra tion, and abr asion. Dryness and n oncorrosiveness of cushioningmaterials are most important since both the item and the cushioning

mat erial will be inclosed in the un it container. Greasepr oof barr iers are

required if the item is preserved. Cushioning mater ials must be secur ed

about th e item. Loose cushioning may resu lt in either t he displacement

of the material when the pack is subjected to shock, its disintegration

under repeated vibration, or the production of dust or loose particles

which will be ent rapp ed within th e pack. Since a cont ainer ma y be

dropped on any of its faces, edges, or corners, the cushioning material

must be designed to withstand the full impact of the entire weight of the

item in a ny direction.




1-51

• Floated Pack. The item is packed in an interior container wh ich in tu rn

is floated in cush ionin g ma ter ials (fig 1-30). This met hod is gener ally

used in connection with semifragile items of medium size and weight.

The item is initially packed (which ma y includ e cushioning or blocking) in

an interior container, then floated in cushioning and placed into an

exterior container . In th is meth od, th e noncorr osiveness and moisture

content of the cushioning materials are not critical since the materialswill not come in conta ct with the item . The use of absorbent cush ioning

mat erials, when used in this m ethod, should be governed a s follows:

When both the interior and exterior containers are water-resistant, the

cushioning material may be simply placed between the two containers. When

either conta iner is nonwater-resistant , the cushioning ma terial mu st be placed in

the form of packs wrapped in a water resistant barrier material. An alternative

for the second case is to provide the interior container with a sealed water-

resistan t wrap and the exterior container with a sealed liner. The cush ioning

mat erial is then placed between th e two barr iers.

SHOCK MOUNTS

The item is cush ioned by mean s of shock mount s. This meth od is used t o cush ionfragile items and sensitive instruments or mechanisms that can be damaged by

shock an d vibrat ion. The weight a nd size of the item m ay vary from light an d

small to heavy and large. The shock moun ts ma y consist of elastomeric springs

or rubber blocks. This met hod of cushioning ma y be accomplished in four m ain

ways.

The item ma y be suspend ed directly by mean s of elastomeric springs. The item

may be blocked in a cradle and the cradle suspended by means of elastomeric

springs. The item may be boxed in an intermediate container and the

interm ediate cont ainer su spended by mean s of elastomeric springs. The item ma y

be boxed in an intermediate container and the intermediate suspended by means

of rubber sh ock m ounts.

P ACKING P ROBLEMSThe basic reason for packing any item is to provide enough pr otection against the

hazar ds it is likely to encounter du ring shipment. This minimizes the chances

that damage will occur during the interval between the time the pack leaves the

shipper an d when th e item is placed in use by the receiving activity. It is, of

course, an impossibility to evaluate all the hazards that might be encountered in

transit, as there are too many variables which can affect the condition in which

an item ma y be found upon ar rival at its destination. The guidelines to packing

present ed herein have indicated the principles an d practices th at ha ve been

found satisfactory in giving protection under average handling and storage

cond itions. If th e solut ion of a specific packing pr oblem is not locat ed in th is

section, the following procedures are recommended for shipment from depots:

DOMESTIC SH I P M E N T S

If an item is being sh ipped domestically, pack th e item in a m an ner which closely

duplicates t he pa ck in wh ich t he item was received.




1-52

Fi gu r e 1-30. M e t hods o f cus h i on i ng .

OVERSEA SH I P M E N T S

If shipment overseas is involved, and no previous history of a container in which

the item had been shipped to a similar destination is available, construct a pack

embodying as ma ny as possible of th e principles outlined in th is section. This

pack should be prepared exactly as it would be shipped including complete

preservat ion an d inter ior packing. It is then t ested by subjecting it to the

applicable performan ce tests. The tests ar e based upon th e size as well as the

gross weight of the conta iner since both influence th e am ount of rough ha ndling

the cont ainer will receive. Small, light pa ckages are easier to move tha n th e

larger and heavier packs, and consequently, they can be expected to receive a

greater amoun t of ha ndling. Perform an ce tests are required for the primar y

purpose of determining the adequacy of all the operations entering into

prepar ation of a pa ck. At the conclusion of the tests, performa nce is based on t he

condition of the container, its contents, the blocking and bracing, cushioning,

preservat ion, and other pa cking mat erials. The pack should be examined for any




1-53

damage, noting in particular any obviously weak points which might need to be

strengthened. Usually the container, if constructed according to specifications,

will withsta nd th e rough ha ndling. If, however, the conta iner is damaged, a

study sh ould be made of th e causes. Deficiencies in th e blocking a nd br acing m ay

result in damage to the container, in which case these deficiencies should be

corrected. Other times th e natu re or shape of th e item may cause the container

to fail. Then , th e conta iner sh ould be reinforced. In an y event , when deficienciesbecome obvious, either in th e conta iners, th e conten ts, th e blocking a nd bracing,

cushioning, preservat ion, etc. the pack should be a ppropriately modified and the

test r epeated u nt il no damage occurs which affects t he u tility of th e pack.

P ACKING SMALL, LIGHTWEIGHT ITEMSAs previously pointed out, cushioning materials are frequently employed to block

lightweight items. In some insta nces, however, cush ioning mat erials such as

fiberboar d, are prim ar ily used for blocking. The effectiveness of fiberboar d as

blocking and bracing depends upon its strength and its resistance to moisture

when not protected by suitable moisture barriers. The domestic class of

fiberboar ds will rapidly absorb moistu re with a resulting loss of strength. The

weather-resistant class on the other hand, retains a greater proportion of its

stren gth in th e presence of moisture. Fiberboard is most frequently employed as

blocking in fiberboard containers because the items packed in them are usually

sma ll an d lightweigh t and do not requ ire hea vier types of blocking. Also, th e

container man ufacturer can provide an d fabricate pa ds, cells, tra ys, or pa rtitions

of the same mat erial a low cost.

Both solid and corrugated fiberboard are employed as blocking material, but the

corru gated is used more frequently becau se it has a greater cushioning value an d

because of its lower cost. Occasiona lly, a pa ck will conta in a compar at ively large

void which will necessitate blocking to prevent shifting of the item, In such cases,

a fiberboar d carton ma y be used for blocking th e item in place. The carton u sed

for blocking should be closed and sealed, and must be strong enough to provide

adequa te str ength in a ll directions.

P ACKING LARGE ITE MSLarge items require special attention to adequately secure them within the

container. Such items are anchored to the base of the container and blocked and

bra ced into a secur ed position on th e base. A clear an ce of a least 1 inch is

provided between the end, side, and top panels and the item is seldom blocked

and braced to these panels. Thus, the container mu st have a rigid base and th e

rest of it be mu st free to distort without placing stresses directly on the contents.

ANCHORING TO B ASE OF C ONTAINERS

Crat es for lar ge and hea vy items should have stu rdy bases to which th e items can

be adequately secur ed. Many ingenious met hods have been developed to hold

items to crat e bases. For sill and skid type crat es, it is essential that t he load becarr ied primar ily by the outside skids or sills. This means t hat loads th at cann ot

be secured to the side sills or bases mu st be pr ovided with load bea ring mem bers

that tran smit the load to them.




1-54

Figur e 1-31. Wate rpr oofing of individua l packa ges.

B LOCKING AND BRACING A LARGE I TE M

After the item has been anchored to the base of the container to prevent its

movement in a vertical direction, it is blocked and braced to prevent its

movement in a h orizontal direction. An item should be anchored only to the base,

hence all bracing and blocking should be so secured.

CLEARANCE BE TWEE N ITEM AND CONTAINERWhen an item is blocked, braced, anchored, or tied down to the inside of one face

of a container or to an au xiliary base wh ich, in t ur n, is so secured, a clearan ce of

not less than 1 inch sh ould be provided between th e item an d all members of the

faces of th e conta iner . A minim um cleara nce of 2 inches sh ould be pr ovided

aroun d fragile part s of the item th at m ight be dama ged due to slight distortion of

the conta iner. A minimum 2 inch cleara nce should be provided between items

within floating bag barriers a nd a djacent m embers of th e container.




1-55

WEATHER P ROOF ING THE P ACKAt this point in the sequence of packing operations, it is assumed that a careful

study has been made of the item to be packed; a suitable container has been

selected; blocking, bra cing, and cushioning h ave been designed; an d t he cont ents

are r eady to be placed into the container . The next step is to provide, when

necessary, a protective barrier in the form of a case liner, crate liner, shroud,

wrap, or tar pau lin fabricated from one of several materials. The barr iers areintended to prevent deterioration of the item, and the preservation and packing

materials used to protect it, by excluding the entry of water, by limiting the

entrance of water vapor, or by diverting water from the materials which are

subject to water da mage. In add ition, barr iers will afford protection from dust ,

dirt, and oth er foreign matt er. Barr iers designed to prevent th e entry of water

(waterproof barriers) will not be used when the interior packs have been

individually waterproofed as shown in figure 1-31, nor when the asphaltum in

the bar rier mat erial or sealant s may prove injurious to the inclosed items. The

water-vaporproof protection afforded by caseliners differs from that afforded by a

Method 50 package in th at wa ter a bsorbing desiccant is not used with caseliners.

WEATHER P ROOF ING (CASE LINE RS, WRAPS, AND SHR OUDS)

Except as provided herein, weatherproof liners, wraps, shrouds or other suitable

mean s sha ll be provided in shipping conta iners as necessary to shield the

contents from the effects of water, water vapor, dust, dirt, and other harmful

mat ter. When a completely inclosed barr ier is provided as in t he case of liners

and wraps, all seams should be completely and continuously sealed to offer

protection equal to the barr ier ma terial itself. Barr ier mat erials an d sealants

constructed with asphaltum shall not be used in the presence of mothproofing

chemicals such as par adichlorobenzene an d napht ha lene. Barr ier mat erials an d

sealants constructed of asphaltum shall not be used to protect items subject to

stain or other dam age cau sed by asphalt u nless such items are initially protected

to exclude asph alt.

TYPE S OF WE A T H E R P R O O F I N G B ARRIERS

The par ticular type of barr ier to be used depends on th e type of exterior container

or the inten ded use of the ba rr ier (table 1-8). In selecting th e type of barr ier to be

used , considera tion sh ould be given t o the following:

• Sealed case liners and sealed wraps are used to resist the passage of

wat er an d water -vapor. Fa brication of case liner s is covered below.

• Sealed case liners will not be used in the packing of material unless

specifically a ut horized.

• Crat e liners an d shr ouds are used to shed water from the t op an d sides of

th e item, allowing free circulat ion of air . Shr ouds are fabricated from

waterproof barrier material conforming to PPP-B-1055, Class E or

heavier. The seams are sealed with wa ter-resistant a dhesive conforming

to MMM-A-260. Shr ouds also may be made of ma ter ial conform ing to L-P-378.

It is important that shrouds be secured to prevent damage or loosening by

storms. They should be weight ed if necessary and a rr anged to avoid forma tion of

water pockets. Shrouds should never extend entirely to the base of a crate or to

the ground since the free circulation of air around the enclosed equipment is

thereby prevented.




1-56

Table 1-8. Applicat ion of weat her proofing barr ier mat erials for packing

Use Barrier Ma teria ls

L-P-378 PPP-B-1055 MIL-B-121 MIL-B-131 MIL-B-

22191

Case Liner ....... Classes H-2, H-3(a),

H-4, H-5, L-2(b),and M-1 Wat erpr oof

Types I an d II,

Grade A, Class1 Water proof

Classes 1 and 2

Watervaporproof

Sealed Wraps

and Plastic

Bags

Type I

Water-

proof

Class es B-1, B-2, B-

3, C-1, C-2, C-2(a),

E-1, and E-2

Waterproof

.......... Classes 1, 2, and

3

Watervaporproof

Types II or

III

Waterproof

Crate Liner ......... Classes C-2(a), E-1,

E-2, E-2, H-5, L-

2(b), an d M-1

Watershed

Shroud Types I and

II

Watershed

Classes E -2, H-5,

and M-1 Watershed

Baling ......... Classes B-1, B-2, B-

3, and E-2Watershed

Temporary

Tarpaulin

Type I

Watershed

Class L-4 Wat er-

shed Class P-1

C AS E L I N E R S, OVERWRAPS , AN D P LASTIC B AG S

Flexible waterpr oof or water vaporproof case liner s, overwra p sh eets, an d plast ic

bag liners s hould be fabricat ed an d closed in accordan ce with MIL-L-10547.

They sha ll be fur nish ed in th e following types: Type I, high-top case liner (fig

1-32); Type II, double-top pa d liner (fig 1-33); Type III, overwr ap sheet , an d Type

IV, plast ic bag. Type II liner s may be used wh en a level, rigid sur face exists or

when t he depth of the case liner exceeds 36 inches. Type III overwrap sheets a re

barr iers used around int ermediat e boxes. Type IV plastic bag liners a re used in

the same m ann er as Type I and II case liners.

They are ava ilable also in six gra des as follows: Gra de A, wat erva porpr oof;

Grade B, waterproof, all temperatures; Grade C, waterproof, asphalt laminated

kraft; Grade D, waterproof and greaseproof; Grade E, waterproof, greaseproof,

transparent, all temperatures, and Grade F, waterproof, transparent, all

temperatures.

Table 1-9 shows the barrier material to use depending on the type and grade of

case liner, overwrap, or bag liner required and whether they are to be used for

subsistence or nonsubsistence items.

Case liners should be made large enough so that the weight of the load will be

born e entirely by the container, not by the liner. There should be no tension in

the wa lls or joints of th e liner after it h as been closed ar ound t he cont ents.

Experience has shown that under some conditions, especially when the contents

do not fill the case liner completely, waterproof case liners do more harm than

good by tra pping and holding water r ath er tha n preventing its ent ry. It is not

essential tha t th ere be openings in the sealed liner for th is to ha ppen. If the liner

material has low resistance to watervapor transfer (a common occurrence) water

can enter in th e form of vapor and conden se on items within th e liner. At the end




1-57

of an extended outdoor exposure period, sealed case liners h ave been opened and

found par tially filled with wa ter. When packed items need protection aga inst

water, it is preferable to incorporate the protection in the individual unit

packages in lieu of using case liners.

Linings for Dru ms, Kegs, Bar rels, and Bags. Linings should be provided for

drums, kegs, barrels, or bags when their contents require protection nototherwise provided by the containers against sifting, contamination, or free

wat er. The linin g ma ter ial should conform to PP P-B-1055 or MIL-B-22191.

Fabrication and closure seams should be heat sealed or sealed with adhesive

conforming to MMM-A-260, as applicable.

WATERPROOF AND WATERVAPORPROOF WR A P S

Waterproof and watervaporproof wraps shall be fabricated and sealed in

accordan ce with MIL-L-10547.

UNSEALED WA T E R P R O O F WR A P S

Unsealed waterproof wraps should be applied to shed water while permitting

breath ing and circulation of air.

Table 1-9. Barr ier mat erials for case liners, overwraps, an d plastic bag liners

Use Liners, overwraps,

an d bag liner

Specifica t ion Barr ier mater ia ls

Grade Types Classifica t ion

Subsistence item C

F

I, II, III

IV

PP-B-1055

L-P-378

Classes H-2 thru H-

5, M-1 Type I

Nonsubsistenceitem

A

C

D

E

I, III

I, II, III

I, II

IV

MIL-B-131

PPP-B-1055

MIL-B-121

MIL-B-22191

Classes 1, 2 and 3

Classes E -1, E-2, H-

1 thru H-5, L-2, M-1

Types I an d II,

grade A, class 1

Type II




1-58

Figur e 1-32. Usin g and closing of high top caseliner .




1-59

Figur e 1-33. Double top pad closur e caseliner .

TESTING OF P ACKS

P U R P O S E O F TESTING

The purpose of testing is to prove the adequacy of packaging design and the

workm an ship of fabrication. Testing may be performed in th e research and

development phase or by tests at the operational level. Since containers in the

storage and shipment cycle are subjected to various and constantly changing

storage and shipping hazards, it is difficult to develop complete data for their

design by merely observing the containers in service. Examinations of failures

will reveal the weaknesses and suggest the specific principles of design to

overcome such failures. Since service test s are not perform ed und er cont rolled

conditions, labora tory tests are necessary to simulate field hazar ds. Ea ch test is

designed to reproduce one or more of the stresses encountered in the field.

During the test cycles the sequence of failures can be observed, classified, and the




1-60

weaknesses from which the failur es result determined. By means of such tests

any number of containers can, in turn, be subjected to exactly the same actions,

thus providing the data necessary to produce balanced construction and

workm an ship. On th e following pages ar e described a number of meth ods th at

have been devised for subjecting containers to hazards similar to those

encountered in the field. Both laboratory and field testing are necessary since

there are certain conditions inherent in each method of testing that cannot beduplicated in t he other.

TYPE S OF T ESTS

Development an d testing of packs and containers should be star ted as soon as

possible after initiat ion of item development . Some of th e tests most comm only

used in p roving design ad equacy include th e vibration, rough ha ndling, and cyclic

exposure tes ts (fig 1-34). One or more of th ese test s are u sua lly app licable to the

design of milita ry packs. In ma ny cases the technical activity having design

responsibility, has intervals test s an d procedur es th at are applicable to a specific

design problem. The docum ents m ost genera lly used for test guidance are MIL-

STD-1186. ASTM D 4169, Per form an ce Testin g of Sh ipping Cont ain ers an d

Systems, and ASTM D 5276, Drop Test of Loaded Containers by Free-Fall, should

be referenced.

TESTING (MIL-STD-2073-1)

After an item has been packed in accordance with one of the MIL-STD-2073-1

meth ods, tests ar e conducted to determ ine the effectiveness of the pa ck. The

types of tests condu cted will depend on the par ticular m ethod used. The tests

called for in MIL-STD-2073-1 are not all-inclusive, however, and additional or

different tests are sometimes required. The types of tests specified in MIL-STD-

2073-1 for proving the adequacy of unit protection are the leakage test, rough

han dling test s, cyclic exposure tests, a nd t he h eat-seal seam t ests.

TESTING (MIL-STD-1186)

When packs prepared for shipment in accordance with the detailed requirements

of MIL-STD-1186 are tested for any rough ha ndling required, th ere sh ould be no

settlement or shifting of cont ents. Fu rth er, the testing should cause no dam age

to the cont ents and should not loosen, break , or displace th e an choring, blocking,

or bracing. The testing should not render t he interior containers, wra ps, liners,

barriers, or cushioning ineffectual in providing continued and adequate

protection to the conten ts.

TYPE S OF R OUGH H ANDLING TESTS

The var ious types of rough h an dling tests include: free-fall drop test ; corn erwise

drop test; pendulum impact test; incline-impact test; edgewise drop test;

vibrat ion test; and other s. The part icular test s employed usua lly depend upon

the size an d shape of th e package. Completed packages as prepared for shipmen t

are given a rough handling test when specified. When a rough handling test isrequired, it precedes applicable tests specified to detect leaks and inadequate

seals or closur es an d preserva tive retent ion.




1-61

Figure 1-34. Examp les of conta iner test.

Inspection and tests for leaks in barrier materials, seals and closures, and

preservative retention, when required, are performed on the contained unit

pack(s) following the rough handling test to determine existence or extent of

detr iment al effects. Un less a part icula r test is specified, selection of th e

applicable rough handling test should be in accordance with ASTM D 5639,

Selection of Corrugated Fiberboard Materials and Box Construction Based on

Performance Requirements.

SMALL C ONTAINERS

Only free-fall drop tests an d vibration t ests sh all apply to sma ll containers; both

or eith er vibrat ion test sh all be condu cted at the option of the contr actor. Small

containers are t hose having a gross weight of 110 poun ds or less. Any container

with skids is tested as a large container. Any conta iner holding an item th at h as

a net weight of more tha n 100 poun ds and wh ich is fasten ed to a base within or to

the base of the container will be tested as a lar ge container.




1-62

LARGE CONTAINERS

All rough handling tests, except for free-fall tests, shall apply to large containers;

both or either vibration test shall be conducted at the option of the contractor.

However, tipover test s will ap ply only when a dditiona lly specified. Eith er impa ct

test sh all be conducted at t he option of th e contra ctor. Large shipping conta iners

are those measuring more than 60 inches on any one edge or diameter, or thosewhich when loaded, have gross weights in excess of 150 pounds or those which

have skids.

F R E E -FALL DROP TEST (F IG 1-35)

The pack may be tested in accordance with ASTM D 5276. A drop tester is an y

suitable apparatus which will allow an absolutely free, unobstructed fall of the

container a t th e orienta tion and th e direction requ ired. A lifting device tha t will

not damage the container will be used and a level steel or cement surface to

absorb all shock with out displacemen t will be provided. The height from which

the specimen should be dropped is dependent upon the weight, size, kind of

container, an d level of pack. This test is mean t to simulate t he fall of an item

dropped by a person from a height they would normally use to lift and carry an

item of that size.

The container should be dropped from the designated height onto a steel,

concret e or stone su rface of sufficient ma ss to absorb t he sh ock with out deflection

in such a manner that the designated surface of the container absorbs the full

force of th e fall (fig 1-35). This test sh ould be rep eat ed un til the designa ted

nu mber of drops have been mad e. (The height refers to th e distance from the

steel, concrete, or stone surface to the nearest surface of the container when

suspended prior to the fall.) The fall shall be a free fall, in th at no ropes or other

suspending media are att ached to the conta iner dur ing the fall. If th e container

is of the dr um t ype, th e top and bottom of the dr um sh ould be mar ked so th at t he

circle of the top and bottom is quartered, and the test should be applied to each

quar tered section.

T IPOVER TE ST (F IG 1-34)

The loaded container is placed on its bottom and slowly tipped until it falls freely

(by its own weight) on its side to a smooth level, concrete slab or similarly

un yielding surface. Stru ctura l damage to th e exterior shipping container wh ich

would result in either spilling of contents or failure of the container in

subsequent h an dling is cau se for rejection. This test is mean t to simulat e the

impacts of accidenta lly tipping over a conta iner. It is intended t ha t th e tipover

test be u sed only on cont ainers t hat are susceptible to accidental tipovers.

E DGEWISE DR OP TE ST (F IG 1-36)

The loaded conta iner sh ould be sup ported a t on end of its base on a sill or block 6

inches in height and at r ight a ngles to the skids. The opposite end of thecontainer should be allowed to fall freely from the specified height onto a steel,

concrete, or stone surface of sufficient mass to absorb the shock without

deflection. The test should be app lied twice to each end of th e conta iner . If th e

size of the container and the location of the center of gravity are such that the

drop tests cann ot be made from th e prescribed height, th e height of the sill will be

increased.




1-63

Figure 1-35. Free fall drop test .




1-64

Figur e 1-36. E dgewise-drop test .

C ORNERWISE -DR OP TE ST (F IG 1-37)

The container should be supported at one corner of its base on a block 6” in

height . A 12” block should be placed und er th e oth er corn er of th e same end of

the conta iner. The lowest point of the opposite end of the conta iner should th en

be raised to the specified height for the weight and allowed to fall freely onto a

steel, stone, or concert surface of sufficient mass to absorb the shock without

deflection.




1-65

Figur e 1-37. Corn erwise-drop test .

I MPACT TESTS

Packs having a gross weight exceeding 150 pounds or any dimension exceeding

60 inches, closed for shipment, may be subjected to one of the following guided

impa ct tests. A single impact should be applied to each of two opposite ends. The

tests are performed to simulate railroad jumping or other accidental impacts,

evaluating the adequacy of the blocking, bracing and tie downs used to secure a

load on or a in a rail car.

I NCLINE -IMPACT TE ST (F IG 1-34)

This test in accordance with ASTM D 5277 simulates the abuses encountered by

packs in freight cars or trucks when the vehicles are subjected to the sudden

starts a nd stops.

The pack, mounted on a movable platform dolly which rides on a plane inclined

20 degrees from th e horizonta l, is released from a k nown distan ce up th e incline

an per mitted to strike against a fixed backstop at th e bottom of th e plane. The

magnitu de of impact shock is var ied by using different release points.




1-66

Figure 1-38. Impact t est.




1-67

SU P E R I M P O S E D -LOAD T E ST (F IG 1-34)

The pr ocedur e is ap plicable for determinin g th e a bility of shipping cont ainers to

resist loads such as imposed on the bottom container of a stack of similar

cont ainer in stora ge, or on a container su pporting top dunn age an d superimposed

lading. Test is applicable for determining t he a bility of shipping conta iners to

resist loads su perimposed on t heir tops as imposed by piling without t op dunn age

man y small, heavy packs on a conta iner.

Stackability, with dunnage tests, are conducted by placing a prescribed load on

the top of the container in a manner simulating the effect of similar containers

being sta cked on t op, an d th e load sh all be allowed to rema in in place for 1 h our.

A check shall be made of any changes or breaks in the container, such as

appa rent bu ckling or failur e of members in the sides or ends. Observations

should be made to deter mine if the distortions are enough to dam age or dislodge

the int erior pa cking or conten ts.

The un iformly distribut ed, with out dun nage su perimposed load t est is condu cted

by placing weights not greater than 10 x 10 inches in outside length and width,

on top of the conta iner in a symmetr ical pat tern appr oximating u niform load an d

allowed to remain in place for 1 hour. Measurem ents of distortions sha ll be madeimmed iately before the load is removed. Checks should be made of an y cha nges

or brea ks in th e cont ainer, such a s appa rent buckling of failure of members in the

top, sides or ends.

VIBRATION TE ST (F IG 1-34)

The forces and motions typical of railroad cars, motor trucks, and air

tra nsporta tion can result in vibra tion wh ich frequent ly produces deterioration or

partial crushing of unit or interior packing which reduces resistance to other

shocks, such as impa ct from droppin g, jolting, or bum ping. Testin g can disclose

weakness in assembly of th e packed item. The pack may be vibrat ion test ed in

accordan ce with ASTM D 3580.

VIBRATION (R EPETITIVE SHOCK) T E ST

Test is used to indicate whether or not a package and its contents will withstand

transportation shocks and vibration without damage when the shipment is not

securely tied down to the floor of th e vehicle. The pa ckage is placed on, but not

fastened to, a platform supported on a mechanism that will maintain the surface

essentially horizont al as it vibra tes th e platform. The am plitu de of the vibrat ion

will be 1 inch total. The frequency will be variable within a s a pproximat e ra nge

from 3 t o 5 Hz. Fences, barr icades, or blocking can be a tta ched to th e platform to

keep the package in position without unnecessarily restricting the vertical or

ra tional movement of th e pa ckage. Un less failur e occur s, tota l time of vibrat ion

will be 2 hours if the package is tested in one position; 3 hours if tested in more

tha n one position.

VIBRATION (S INUSOIDAL MOTION) TE ST

Test in accordance with ASTM D 4169 is used to determine the adequacy of

packages that contain items susceptible to damage from vibration encountered

dur ing shipping an d are tied down to the floor of the carr ier. The package is

attached securely to a platform supported on a mechanism that will maintain the

surface essentially horizontal as it vibrates the platform vertically. Controls are

provided to vary th e frequ ency form 2 to 500 Hz as specified. If th e package

might be shipped in more than one position, the package will be tested in each

position.




1-68

S IMULATED CONTENTS

Simulated contents of the same dimensions, weight, center of gravity, and

physical properties as the actual contents may be substituted in the tests

described above. A shock-recording inst ru men t of an a ccepta ble type should be

appr opriately installed within the shipping conta iners. This provision is

intended to avoid unnecessary damage or complete destruction of valuable

commodities.

I NTERP RETATION OF R ESULTS

All ma ter ials an d componen ts sha ll be free from dam age or eviden ce of

displacemen t which affects th e ut ility of th e pack. When specified, functional

tests should be conducted on the items or equipment to determine freedom from

opera tiona l m alfun ction.

MARKING OF P ACKSMarking permits ready identification of military supplies and equipment for

shipment a nd storage. No mat ter how well an item is made or packed, it is

valueless if it cann ot be identified u pon rea ching its destinat ion.

ASTM D 996, Standard Terminology of Packaging and Distribution

Environments, defined marking as "the applications of numbers, letters, labels,

tags, symbols, or colors to provide identification and to expedite handling during

shipment and storage".

MARKING STANDARD

The publication that provides the requirements for the uniform marking of

militar y supplies and equipment is Military Sta nda rd 129, Marking for Shipment

and Stora ge. This publication is appr oved for use by all Depart ment a nd

Agencies of the Depart ment of Defense. It a ccommodates th e requiremen ts for

coded an d in th e clear da ta an d th e forms required by DOD 4500.25-1-M, Militar y

Standard Requisitioning and Issue Procedures (MILSTRIP); DOD 4000.25-2-M

Military Standard Transaction Reporting and Accounting Procedures

(MILSTRAP); and DOD 4500.32-R, Militar y Sta nda rd Tran saction an d Movement

Pr ocedur es (MILSTAMP).

All required marking and any additional special marking which may be required

depending u pon th e item a nd container being shipped (fig 1-39) can be foun d in

MIL-STD-129.

ECONOMY IN P ACKING

STANDARDIZATION

Economy in packing is the responsibility of everyone concerned with military

supply. The Secretary of Defense ha s established policies on pa ckaging th at mu st

be followed. These policies empha size th at th e militar y services sta nd ar dize th eirpreservation, packaging, and packing. For example, the services, by using

packaging standards, assure the same requirements for the same type of items,

thus reducing the number of materials, methods, and procedures - whether these

requiremen ts ar e performed by th e contr actor or by th e depot.




1-69

Figure 1-39. Shipping container identification, address,

and special mar kings.

F ALSE E CONOMY

Defense material must be protected against all hazards at the lowest possible

cost, with the tar e weight an d cube kept to a minimum . Any att empt, however,

to relax stan dar ds to anything less than adequa te, is false economy. To associate

the size and price of an item with the cost of packing is also false economy. Items

of small size or low monetary value are often essential to the proper function of a

million dollar a ssembly. To use more mat erial or more expensive material th an

is essen tial is a lso false economy.

R EDUCING TAR E WEIGHT AND CUBE

One important way to reduce overpacking is through the use of pilot packs

carefully engineered and tested for a par ticular item. The redesigning of

established packs and the use of standardized processing forms may result in

substa ntial savings. Wherever the selection of th e container is optional, study

the comparative initial cost, the labor handling and storage costs, and any

possible reduction in tare weight a nd cube. Probably no area is more fru itful in

realizing savings th an in th e reduction of tar e weight an d cube.

P OTENTIAL AREAS FOR E CONOMY

There are two ar eas of great saving potent ial. One is repair par ts and genera l

stores items which account for the greatest shipping volume through high

tur nover. The other is items of large cubic volume on which sh ipping cha rges are

high, such as pontoons, fuel tanks, electronic equipment, and machine tools.

Figure 1-40 shows an example where savings in weight and cube, together with

reduction in top heaviness, were achieved by remounting the item on its side.

The length of the crate framing members and diagonals was reduced, and the

basic strength of the crate was increased by having the angles of the diagonals

near er to the ideal 45 degree.




1-70

Figure 1-40. Savings achieved through crating of an item .




1-71

Use the most economical container t ha t will adequately han dle the load. For

example, do not use a Style 2 wooden box having a load limit of 1000 pounds,

when a Style 4 box with a load limit of 400 pounds will give all the protection

needed. Do not use a wooden box when a lighter cont ainer is adequa te for th e

pack.

Develop an active training program for packing supervisors and personnel to

alert th em to the consta nt n eed for the redu ction of weight a nd cube. Figure 1-41

shows how saving in weight, cube, and m ater ials resulted from a simple redesign

of th e pack.

Make a vailable a greater selection of light weight conta iners on th e packing lines.

Operat ors will not be as likely to use hea vier cont ainers when fiberboar d or other

lightweight conta iners ar e available and can do just as well.

Consolidate multipack shipments into low cost containers to eliminate the

shipping weight of smaller individua l containers. The wood, wireboun d, and

triple wall fiberboard pallet boxes are all light in weight, are economical andsuitable for consolidat ing mat erials for domestic and air sh ipments.

OT H E R E CONOMY AREAS

There a re several other area s in which economies can be achieved.

MANPOWER

Any reduction in manpower cost will have a definite bearing on the economy of

packing. One way to reduce manpower cost is to recognize that th e well tra ined

packer is the economical packer. This means using the right m an on the right

job.

MECHANIZATION

Savings of considerable importance can be derived from the proper use of

mechanization. Powerized conveyor belts, mechanized ha ndling systems, and

automatic packing machinery, all help to reduce handling and speed up

operations.

R EUSE OF MATERIALS

Another field in which savings can be effected is th rough t he sa lvage an d r euse of

mat erials. Lumber, cush ioning, blocking and bra cing materials, containers, an d

meta l fasten ers can be reused with a little careful plann ing (fig 1-42).

P a r c e l P o s t

One other area for achieving savings is the more efficient use of parcel post.

Frequ ently, par cel post redu ces th e n eed for docum enta tion, allows a lowering of the level of protection, cuts down on marking requirements, and permits faster

delivery. Remember, to obtain t he m aximum value for each Defense dollar , one

must be awake t o every new idea th at m ay lead to the r eduction in pa cking costs.




1-72

Figure 1-41. Savings achieved by redesigning a cont ainer.

P AR C E L P OS T R E QUI R E ME NTS

GENERAL SU P P L I E S Military requirements for parcel post shipments must conform to the Postal

Service Manu al an d th e various Armed Service regulations.

Nonm ai l ab l e M a t t e r

Nonmailable matter includes all matter which is by law, regulation, or treaty

stipulation, prohibited from being sent in t he m ail or wh ich cann ot be forwarded

to its dest ina tion because of illegible, incorr ect, or in sufficient add ress .




1-73

Figure 1-42. Reusing packaging mat erials means economy.

H a r m f u l Ma t t e r

With certain exceptions, any articles, compositions, or materials, which may killor injure another or injur e the mail or other pr operty, are nonma ilable. This

includes but is not limited to--

• All kinds of poisons, including controlled subst an ces.

• All poisonous animals, except scorpions, all poisonous insects, all

poisonous r eptiles, and all kinds of sna kes, tur tles and spiders.

• All disease germs an d scabs.

• All explosives, flammable material, internal machines, and mechanical,

chemical, or oth er d evice or compositions wh ich m ay ignite or explode.




1-74

GENERAL E XAMPLES OF H ARMFUL MATTER

Harmful matter includes, among other things, that which is likely to destroy,

deface, or otherwise damage the contents of the mailbags or harm the person of

an yone en gaged in th e Postal Ser vice, such a s caust ic poisons (acids an d a lkalis),

oxidizing materials, or highly flammable solids; or which is likely under

conditions incident to transportation to cause fires through friction, through

absorption of moisture, through spontaneous chemical changes or as a result of retained heat from manufacturing or processing; explosives or containers

previously used for shipping high explosives having a liquid ingredient (such as

dynamite), ammunition; fireworks; highly flammable liquids or substances;

rad ioactive ma terials; matches; or a rticles emitting a bad odor.

H ARMFUL MATTER R EQUIREMENTS

Harmful items should not be shipped parcel post without prior approval of the

Postal Service. Whenever th ere is doubt a bout t he ma ilability of a par ticular

item, a request for a r uling should be mad e to the local postmaster . Mailability

ru lings ma y also be obtained from a near by mail classification center or from the

Office of Mail Classification, US Posta l Service, Washin gton, DC 20260.

TYPE S OF SH I P P I N G C ONTAINERS

G e n e r a l

Postal regulations require containers strong enough to retain and protect their

conten ts from th e weight of other mail.

C o m m o n C o n t a i n e r s U se d

The following containers, with applicable specification are most commonly used,

depen ding on size, weight , and na tu re of th e art icle(s): Cotton Mailing Bags (A-

A-2714); Burlap Cotton and Waterproof Laminated Textile Shipping Bags (A-A-

881); Folding Boxes (PPP-B-566); Fiberboard Boxes (ASTM D5118); Sacks,

Shipping, Paper, Cushion (A-A-1588) and Cans, Fiber, Spirally-wound (MIL-

C-3955).

M ai l bags

Mailbags ma y be used a s conta iners for consolidated shipment s of un breaka ble or

nonfragile items going to the same location, provided projections are cushioned to

prevent ru ptu re of th e bag dur ing shipmen t. Use of one of th e three available

sizes of mailbag should be based on volume of material going to individual

customers.

U s e d Co n t a i n e r s

Used cont ain ers in good rigid condition with all flaps int act ar e accepta ble. If a

container of desired size cannot be found, a large one may be cut down to meet

the n eeds.

Si ze an d Weigh t o f Con t a i ne r

The shipping containers must be of the proper size to accommodate the item(s)

being shipped. Su fficient spa ce for cush ionin g ma ter ial should be allowed at t he

time of container selection, avoiding both the underpacking and overpacking of

the item and rem aining with in the weight limitat ions. The size and weight of

packages mailed at most post offices is limited to 108 inches, length and girth

combined, an d 70 pounds.




1-75

M e a s u r e m e n t

Comput e th e size of a par cel as follows (see Figur e 1-43):

• Measure t he longest side.

• Measur e the distance around th e parcel at its th ickest par t (girth).

• Add both measur ements.

Some military post offices overseas have more restrictive size and weight

requiremen ts. The weight of an addr essed piece of parcel post must be 16 ounces

or more.

R e u s a b l e Co n t a i n e r s

The use of reusable containers may be determined by considering the following

factors:

• When the military characteristics of the item are such that a reusable

type container is necessary. When th e container can ser ve a dual pur pose

of shipping container a nd case while th e item is in u se. When th e item is

designa ted a s r ecoverable-repaira ble item.

• The cost of a reusable container is offset by multiple use as compared toth e cost of single tr ip, disposable conta iner s.

• When the cost of the item and/or its critical characteristics, or the need

for periodic inspection or exercising justifies the use of a reusable

container.

Reusable drums with protruding closure devices, such as locking rings, shall be

cushioned t o prevent injur y to postal employees, equipment or other m ail.

O u t s i d e Wr a p p i n g a n d C l os u r e

When a box itself is an adequate shipping container, paper wraps should be

omitted. If a paper wra p is used as an outside cover for boxes, the pa per should

have at least 60 poun ds basis weight. Closure a nd reinforcement sh ould be made

by the u se of tape.

Closure and reinforcement is accomplished by using gummed and pressure-

sensitive tapes, adhesive, stra pping, an d staples for boxes and bags. Various

friction closures, screw caps and locking devices for cans and similar containers.

General purpose transparent mending tape and masking tape shall not be used

for closure or reinforcement, but may be used to augment adhesive closure on

envelopes or to cover sta ples on ba gs. Pressu re sen sitive filament reinforced tape

or reinforced paper t ape is recommen ded for closur e an d reinforcement. Except

for pressure sensitive filament tape, tapes used for closure and reinforcement

shall be not less tha n 2 inches wide.

When strapping is used for closure and reinforcement, it should encircle thelength an girth of th e package at least once. Twine and cord should not be used.

Loose strapping is not acceptable because it presents a hazard to employees and

equipment a nd does not reinforce the conta iner.




1-76

Figure 1-43. Post office measur ement r equirement s.

M ar k i ng o f Pa r ce l s an d U.S. M a i lbags

Par cels shall be m ark ed to sh ow the consignor; consignee; Tran sportation Contr ol

Number (TCN); and required delivery date, project code, and mark for, when

specified.

Marking of U.S. mailbags shipped both domestically and overseas should be

tagged in the space located on the locking device to prevent possible opening in

tra nsit. Suggested wording of the tag is "OFFICIAL MAIL FOR

ORGANIZATION OF ADDRESS. DO NOT OPEN IN TRANSIT."

In addition to the postage tag located on the locking device of the mailing bag, an

additional tag will be atta ched. The ta g will notify the local postal aut horities

that the bag is to be delivered intact to its destination and will contain the

complete addr ess to which the bag is destined and th e retur n addr ess.




2-1

C H AP T E R 2

FIBE RBOARD AND P AP ER BOARD CONTAINERS

FIBE RBOARD BOXES

DE S C R I P T I O N O F F IBERBOARD BOXES

A fiberboard box is a container made of one or more pieces of corrugated or

solid fiberboard . The pieces are creas ed, slott ed, joined, an d folded according

to standard styles described in ASTM D 5118, ASTM D 1974 and illustrated

in figures 2-6, 2-7, 2-8, and 2-9.

US E O F F IBERBOARD BOXES

The quantity of fiberboard boxes used in military shipments are increasing

stea dily an d rapidly. A fiberboar d box weighs considera bly less th an a

wooden box of th e sam e cap acity. This differen ce in weight is a factor wh enlarge shipments are involved, as any saving of weight is reflected in lower

shipping cost and easier handling. The main requirement s for a shipping

container are light weight, low cost, ability to withsta nd r ough ha ndling, and

ability to protect the cont ents against loss or damage. Motor trucks,

airplanes, container cars, skid platforms, lift trucks, platform slings, and

palletized loads have been important factors in reducing transportation and

han dling hazar ds, thu s expanding t he u se of lightweight fiberboard boxes.

Advant ages in the Use of Fiberboard Boxes. Fiberboard boxes are ada pta ble

to a great var iety of packa ging an d pa cking cond itions. They offer th e

following advantages:

• They are made of materials of exactly the specified strength andwater resistance.

• They are pr efabricated.

• They are made in several styles to suit different shapes and sizes of

items.

• They are shipped and stored in the flat, and hence save shipping and

storage spa ce.

• They are easy to assemble and ha ndle.

• They are light in weight an d relatively strong.

• They are neat in appeara nce and easy to mark.

• When packed, they occupy less space than most other containers of

the sa me inside dimensions.

C LASSIFICATION OF F IBERBOARD BOXES

Fiberboard boxes, for domestic and oversea shipments, have been

consolidat ed under ASTM D 5118 and ASTM D 1974. Fiberboard mat erial

mu st conform to ASTM D 4727. Boxes may be procur ed or fabricated in th e

following t ypes a nd classes :

• Types (see fig 2-1)

ο Type CF Boxes - Type CF boxes are fabricated from

corru gated fiberboar d (CF) stock. Corr ugated fiberboar d ha s




2-2

two var ieties: Single-wall (SW) an d double-wall (DW)

construction.

ο Type SF Boxes - Type SF boxes are fabricated from solid

fiberboar d (SF).

• CLASSES

ο Domestic class boxes are made to meet the requirements of

table 1, ASTM D 4727 for burst ing stren gth a nd t he weight of

th e facing mat erials. (See figur e 2-1, ta ble 2-1.)

• Corrugated fiberboard, class weather-resistant (WR), and

waterproof and water vapor resistant (WWVR) - The WR and

WWVR boxes, both single and double wall, will meet the bursting

strength and thickness for the grade and variety as described in

ta ble 2, ASTM D 4727. (See figure 2-1, ta ble 2-2).

Gr a des o f fi be r b oa r d

Different str engths of fiberboar d are indicated as grades. Grades of

fiberboard for class domestic are types CF an d SF . Type CF is different iatedby PSI (poun ds per squar e inch) of bursting st rength (tables 2-1 th rough 2-4).

Weather-resistant grades of fiberboard are identified by a letter-number

combina tion such a s V2, V3, W5, an d W6 which repr esent different burst ing

stren gths. The num eral in each combina tion represent s the gra de of ma terial

and th e letter in each combina tion represen ts a kind of fiberboar d (V- or W-

boar d). V-board is a heavy-dut y, highly weath er-resistant board, and W-

boar d is a lower st rength , highly weath er-resistant board (see table 2-2).

Type CF (corrugated fiberboard) can be obtained in grades 3, 5, 6, 11, 13, and

15, with complian ce symbols of V3c, W5c, W6c, V11c, V13c, an d V15c. The

sma ll “c” indicates corr uga ted fiberboard .

Figur e 2-1. Classificat ion of fiberboar d boxes.




2-3

Type SF (solid fiberboard) can be obtained in grades 125, 175, 200, 275, 350,

500 and 600 with compliance symbols of V2s, V3s, V4s, W5s, and W6s, as

shown in figure 2-1, tables 2-3 and 2-4, which are taken from ASTM D 4727.

The sma ll “s” indicat es solid fiberboar d.

Waterproof and water vapor resistant (WWVR) grades of fiberboard are

identified by a letter-number combination followed by the letter "WWVR".Waterproof and water vapor resistant boxes are fabricated from type CF

(corrugated fiberboard) and can be obtained in grades V3c, W5c, V15c, and

W6c (each followed by “WWVR) in th e single wa ll variety a nd gra des V11 an d

V13 (each followed by “WWVR”) in the double-wall variety.

Table 2-1. Type CF (Corrugated Fiberboard), Domestic

Variety Grade

Combined Weight

Fa cings Only, min

Bursting Strength, Dry,

min A

lb/1000 ft 2 (g.m2) psi (kPa)

SW 125 52(254) 125(862)

SW 150 66(322) 150(1034)

SW 175 75(366) 175(1207)

SW 200 84(410) 200(1379)

SW 275 138(674) 275(1896)

SW 350 180(879) 350(2413)

DW 200 92(449) 200(1379)

DW 275 110(537) 275(1896)

DW 350 126(615) 350(2413)

DW 500 222(1084) 500(3447)

DW 600 270(1318) 600(4137)

Puncture

in. oz/inches

of tear (J)

TW 1100 264(1289) 1100 (33)

A Only one burst of th e initial six may fall beneat h th e minimum r equired. Domestic board

failing to pass this test will be accepted if, in a retest consisting of 24 bursts (12 from each side of th e boar d), not more tha n 4 burst s fall below the minimu m value required.




2-4

Table 2-2 Type CF (Corrugat ed Fiberboard), Weath er-Resistan t, and Wat er an d Water Vapor

Resistant Classes (WWVR)

Thickness, in. (mm )B Bursting Strength, psi (kPa), min

avg

Variety GradeA,C Corrugating

Medium

Outer Facings Dry Wet D

SW V3c 0.010(0.254) 0.023(0.584) 400(2758) 150(1034)

SW W5c 0.010(0.254) 0.016(0.406) 275(1896) 100(689)

SW W6c 0.010(0.254) 0.010(0.254) 175(1207) 50(345)

DW V11c 0.010(0.254) 0.023(0.584) 600(4137) 300(2068)

DW V13C 0.010(0.254) 0.016(0.406) 400(2758) 200(1379)

DW V15c 0.010(0.254) 0.010(0.254) 300(2068) 100(689)

A Includes WWVR gra des.

B A - r%, or u nlimited plus tolerance sha ll be permitt ed.C For doublewall fiberboard, th e inner facing shall be the sa me th ickness a s th e out er facing.D After 24 h immer sion (see 9.2.1)

Table 2-3 Type SF (Solid Fiberboar d): Class Domestic, All Gra des

Grade Combined Weight of Plies Before

Lam inat ion, lb/1000 ft2(g/m2), min

Bursting Strength, psi (kPa),minA

125 114(557) 125(862)

175 149(727) 175(1207)

200 190(928) 200(1379)

275 237(1157) 275(1896)

350 283(1382) 350(2413)

500 330(1611) 500(3347)

600 360(1758) 600(4137)

A Only one burs t of th e initial six ma y fall beneath the m inimum requir ed. Domest ic board failing to pass

this test will be accepted if, in a retest consisting of 24 bursts (12 from each side of the board), not more

tha n 4 burst s fall below the minimum value required.




2-5

Table 2-4 Type SF, Class Weath er-Resistant , All Grad es

Grade Thickness, in . (mm)A Bursting Strength, psi (kPa)

V2s 0.090(2.29) 550(3792) 500(3447)

V3s 0.090(2.29) 400(2758) 150(1034)

V4s 0.080(2.29) 400(2758) 150(1034)

W5s 0.075(1.91) 275(1896) 100(689)

W6s 0.060(1.52) 175(1207) 50(345)

A A" 10% toleran ce shall be perm itted.

Capa b i l it i e s o f F i be r boa r d Boxes

The th ree pr incipal factors a ffecting th e carrying capacity of corrugat ed a nd

solid fiberboard boxes are resistance to compression, strength at the score

lines, and resistan ce to puncture. A four th factor th at sh ould be taken into

consideration is the ability of fiberboard to resist the weakening effect of

moistur e. The importa nce of th e first th ree factors varies according to the

commodity for which a particular box is designed, and the type of interiorpacking employed.

Resistance to compression, for example, is a relatively minor factor when the

contents support the walls of the container or when the interior packing

fur nishes the necessary support. When these factors ar e not present, the

shipper must make certain that the container has sufficient resistance to

compression t o prevent it from caving in wh en it is placed in t he bottom t ier

of a pile of similar boxes. Corru gat ed an d solid fiberboar d boxes ma y be used

to ship articles that are not readily susceptible to damage resulting from

ordinary distortion of th e container. The man ner in wh ich a commodity is

packed governs to a great extent its condition on arrival at destination.

Therefore, the selection of the proper style, class, and grade of fiberboard box

should be carefully considered to ensure the commodity against the hazards

of storage, shipment, an d ha ndling.

The items normally packed in fiberboard boxes are type 1 or type 2 loads.

Type 3 loads should be converted to type 1 or type 2 loads by proper interior

packing.

Us es and L i m i t a t i ons o f C l a s s Dom es t i c F i be r b oa r d Boxes

The uses of fiberboar d boxes ar e essent ially as indicated above. Man y

variations of special die-cut inserts, scored pads, and partitions can be

fabricated to give add itional pr otection to th e item. The colum ns for

corrugated and solid fiberboard (CF and SF) show the minimum bursting

strength of the fiberboard in pounds per square inch which determines thegrades.

Us es and L i m i t a t i ons o f C l a s s Wea t h e r - r e s i s t an t a nd WWVR F i be r boa r d Boxes

V-board was developed primarily for the fabrication of exterior containers for

oversea shipment. W-board was developed primarily for the fabrication of

interior containers which are packed in exterior containers for oversea

shipment . At oversea point s, the exterior pa ck is sometimes rem oved and t he

W-board boxes become th e exter ior conta iners . When W-board boxes are

used as exterior containers, their weight and dimensional limitations should




2-6

not be exceeded. Although both V- an d W-board s are h ighly water resistan t,

boxes made from these materials will permit the entrance of water through

the corn ers and joints. When packed items ar e of such a nat ur e as to be

dama ged by water, wat erproofing is provided by the u se of individua l wraps

of ma ter ial conforming t o PPP -B-1055; by th e use of case liners conformin g to

MIL-L-10547; or by the use of waterproof, pressure-sensitive tape conforming

to ASTM D 5486, applied as shown in figure 2-2 after proper closure of thebox. In accorda nce with ASTM D 5118, ta bles 2-5 an d 2-6 are used t o

determine the weight and size limitation when class weather-resistant

fiberboar d boxes ar e requ ired. Compliance symbols ar e given in the first

column.

Figur e 2-2. Sealing Method B.




2-7

Table 2-5 Size an d Weight Limita tions for Types CFA and SFA Domestic Fiberboar d Boxes

Type CF Variety Type SF Max Weight of Boxes Max Inside

Dimensions

SW4 DW4 and Contents Length + Width +

Depth

Grade Grade Grade lb (kg) in .

125 .......... 125 20 (9.1) 40

150 .......... .......... 30 (13.6) 50

175 .......... 175 40 (18.1) 60

200 200 200 65 (29.5) 75

275 275 275 90 (40.8) 90

350 350 350 120 (54.4) 100

500 500 140 (63.5) 110

600 600 160 (72.6) 120

A Explana tion of abbreviat ions in Table 1

CF - Corrugated Fiberboard

SF - Solid Fiberboard

SW - Singlewall Fiberboard

DW - Doublewall F iberboar d

Table 2-6 Size and Weight Limitations for Class Weather-Resistant (WR) and Water/Vapor

Resistant (WWVR) Fiberboard Boxes Used a s E xterior Cont ainers A

NOTE - The gross weight and size limit expressed in the circular or rectangular boxmaker's certificate

shall conform to the requirements of the Uniform Freight Classification or National Motor Freight

Classificat ion Rules, as a pplicable, and m ay not necessar ily be the sa me as those stipula ted in Table 2.

GradeB (Compliance

Symbol)

Max Weight of Boxes and Contents Max Inside Dimensions Length + Width

+ Depth

lb (kg) in. (mm)

V2s 120 (54.4) 100 (2540)

V3s, V4s, and V3c 90 (40.8) 90 (2286)

W5s and W5c 65 (39.5) 75 (1905)

W6s and W6c 30 (13.6) 30 (762)

V11c 160C (72.6) 120 (3048)

V13c 120 (54.4) 100 (2540)

V15c 90 (40.8) 90 (2286)

A Not applicable to interior boxesB Referen ce Specification D 5118/5118M for specific deta ils of const ru ctionC Maximum weight ma y be increa sed to 225 lb (102 kg) provided th e ma nufactur er's body joint is fast ened

with met al fastener s spaced not more than 1 in. (25 mm) apar t (see 8.1.8)




2-8

MATERIALS

C o r r u g a t e d F i b e r b o a r d

Corrugated fiberboard is fabricated of flat sheets of paperboard (called

facings) glued to the crowns of a corrugated sheet of the same material.

Strength requirements are obtained by varying caliper, number, and quality

of th e component facings and th e corrugat ed medium. Corru gated fiberboardhas low resistance to puncture but affords a high degree of resilience and

cushioning. Single-wall (SW, also called double-faced), corr uga ted fiberboar d

consists of two outer paperboard facings laminated to a corrugated sheet

between t hem (fig 2-3). Double-wall (DW) corru gat ed fiberboar d consist s of

three flat facings and two corrugated sheets, a center facing, a corrugated

sheet , an d a facing (fig 2-3). It is this combina tion of flat a nd corr uga ted

sheets that gives corrugated fiberboard its qualities of strength and

resilience. Corru gated fiberboard is constr ucted with different k inds and

arr an gements of flutes. The "A" flut e, with 36 plus or minu s 3 flutes per

linear foot, is gener ally used wher e cush ionin g of cont ent s is desired. The "B"

flute, with 50 plus or minus 3 flutes per linear foot, is used where the

cont ent s tha t su pport t he box ar e of low fra gility. The "C" flut e, with 42 plus

or minus 3 flutes per linear foot, can be made to serve either propose. The"E" flut e is 94 flut es per foot, plus or m inu s 4 flutes (fig 2-4). The "A" flut e is

the largest of the three and its strength is realized in stacking applications.

Its ability to withst and impact as well as its resistan ce to flat crushing is th e

lowest of th e four flut e sizes due to th e lesser n um ber of flut es per linear

span. The smallest stan dar d flute size, "E", is the weakest in terms of

stacking strength, but it performs very well under puncture and flat crush

str ess. The "C" flut e, which is the middle size flute, will perform moder at ely

well in all th ree areas--stacking, puncture, and flat cru sh. It is used where

maximum strength in any one area is not required, but where weakness in no

area can be tolerat ed.

Figur e 2-3. Types and var ieties of fiberboar d.




2-9

Figure 2-4. Corru gated fiberboar d flutes.

D o m e s t ic F i b e r b o a r d B o x es

Variety SW fiberboard used to fabricate type CF boxes will be A, B, C, or E

flute at the option of the supplier. Variety DW fiberboard used t o fabricate

type CF boxes will be any combination of A, B, C, or E flutes, except they

sha ll not be BB, EE , or BE flute. Type CF boxes, fabr icat ed from var iety SW

or DW fiberboard sh all have th e flutes r un ning perpen dicular to the scores of

th e box open ings. When sp ecified, th e flutes for variet y SW or DW fiberboar d

will run horizontal to the scores of the box openings for boxes of a size that

the t op and bottom openings are on the sma llest pan els.

Weat h e r - Res is t an t And WWVR F i be r boa r d Boxes

Variety SW fiberboard used to fabricate type CF boxes will be either A, B, orC flute as specified. Conventional slotted type CF boxes shall have the flutes

ru n perpen dicular to th e scores of th e box openings. When specified, th e

flut es for t hese boxes sha ll run horizonta l to the scores of th e box openings for

boxes of a size an d style tha t t he t op and bottom openings are on t he sm allest

pan el. For Styles DBLCC an d IC boxes (fig 2-7), th ey shall have th e flutes

ru n th e depth of the box perpendicular to the opening.

So li d F i be r boa r d , Type SF

Solid fiberboard consists of two or more flat plies of paperboard laminated

together with an adh esive applied over the en tire ar ea of contact between th e

sheet s (fig 2-3). The combined m at erial is solid, ha rd, an d rigid, an d boxes

fabricated from it r esist pun cture t o a h igh degree but offer little cushioning

to th eir conten ts. They do, however, offer grea ter resist an ce to rough

handling and wear, and are better adapted for use in shipping heavier and

less fra gile items tha n th ose shipped in corrugat ed fiberboard boxes. If the

weight of the box and contents does not exceed 40 pounds, the fiberboard will

not be less tha n two-ply. If th e weight exceeds 40 poun ds, the fiberboard will

be not less th an th ree-ply.

T a p e s

Among the tapes most commonly used for closing and sealing fiberboard

boxes a re--




2-10

• ASTM D 5486, a pressure-sensitive water-resistant, paper-backed

ta pe, norma lly used to close inter ior conta iner s. ASTM D 5486 is also

a pressure-sensitive waterproof tape, used to close and waterproof

interior a nd exterior fiberboar d boxes.

• A-A-1492, A-A-1671, a reinforced, paper-gummed tape, used for

sealing fiberboard conta iners for d omestic shipment an d storage.

Adhes i ve

Adhesive used for closing fiberboard boxes will conform to MMM-A-250.

M et a l fa s t en i ngs

Metal fastening for securing the manufacturer's joint and closing class

weather-resistant and WWVR fiberboard boxes, will be commercially

preformed sta ples or staples from commer cial steel stitching wire. The

staples will be treated with a commercially applied coating of zinc or copper

wash to resist corrosion. ASTM D 5118 and ASTM D 1974 specifies th e sizes

of sta ples to use.

R e i n fo r c i n g m a t e r i a lsFlat steel strapping ASTM D 3953; nonmetallic strapping, ASTM D 3950; or

pressure-sensitive, filament-reinforced tape ASTM D 5530 are used to

rein force packed and closed fiberboar d boxes. Another documen t to referen ce

is ASTM D 4675, Standard Guide for Selection and Use of Flat Strapping

Materials.

Fa br i ca t i on o f t he Boxes

Cutt ing, scoring, and slotting. Special machines are u sed to cut, score, and

slot t he fiberboard ma terial so tha t it can be made int o a box.

Body j oi n t ( m an uf ac t u r e ' s jo i n t )

Domestic boxes, types CF and SF. The body joint (man ufactu re's joint) of

domestic, corrugated fiberboard boxes will be either overlapped or butted, as

specified (fig 2-5). The type SF joint sha ll be overlap ped.

O v e r la p p e d J o i n t (J o i n t Ta b )

The joint sh all be made with fiberboard joint t ab overlap not less th an 1 1/4

in. (32 mm) wide with the length of the overlap equal to the inside depth of

the box. The joint ta b may be an exten sion of either th e end or side pan el of

the box. When specified the joint ta b may extend into the flap ar ea an d be

secur ed. The joint ta b shall be fasten ed either inside or outside th e adjoining

panel and the top and bottom edges of the front tab shall be no more than

3/16 in. (5 mm) below th e top or above the bottom scoreline of th is pan el. The

overlapped joint of type CF boxes shall be fastened with adhesive. The

toxicity requirement may be waived when packing items other than food.When a dhesive is used it sh all be applied so as to cover th e full area between

the joint tab and the adjoining pan el. The adhesive shall substa ntially

exten d to all edges of th e overlap . The overlapped joint of type SF boxes sha ll

be fasten ed with met al fasten ers. Metal fasten ers for the type CF and t ype

SF boxes having a depth dimension of 18 in. (457 mm) or less shall be spaced

not more tha n 3 in. (76 mm) apart center to center .




2-11

Figur e 2-5. Body joint s for fiberboard boxes.

Metal fasteners for the type SF box having a depth dimension greater than

18 in. (457 mm) shall be spaced not more tha n 2 2 in. (64 mm) apa rt center to

center . The distance between th e ends of the joint an d the near er end of thenear est fasten er shall not exceed 1 in. (25 mm). Metal fasten ers may be

applied diagonally, vertically or horizontally at the option of the supplier.

Weat h e r - r e s i s t an t a nd WWVR Boxes , Type CF a nd SF

The lap joint sha ll be used on weat her-resistant an d WWVR grade boxes (fig

2-5). The lap joint will overlap either in side or outside th e box not less th an 1

1/2 inches, an d will be secur ed with st eel staple or steel stitching wire. The

staples or stitches will be spaces not more than 2 inches apart, and the

distance between th e outer st itches a nd t he en d of the joint will not exceed 1

inch. An additiona l tie-stit ch will be used a bout 1/4 to 3/4 inch from ea ch end

of th e joint .

In lieu of a tie-stitch joint, boxes may be stapled or stitched with the samenumber of fasteners (including tie-stitches) equally spaced in a single row.

When specified, th e body joints of gra des W5c, W6c, a nd V3c fiberboard boxes

ma y be secured by t he u se of adh esive conform ing to MMM-A-250.

B u t t e d J o i n t (T y p e C F O n l y)

The but ted joint sha ll be ma de by fitting th e edges of the pa nels to be joined

closely together a nd secur ing them with gumm ed tape. Tape used to secur e

th e body joint of boxes ha ving gross weight , of 40 lb (18 kg) or less (grade 125

to 175) shall be tha t n ormally used by th e industr y for this pur pose.




2-12

Tape used t o secur e th e joints of boxes having a gross weight of more tha n 40

lb (18 kg). (Grades over 175) shall be reinforced with sisa l, cloth, glass, ra yon

or double stra nd n ylon fibers. The ta pe shall be not less than 2 in. (51 mm) in

width for boxes having a gross weight of 65 lb (30 kg) or less (grade 200 and

below) and not less than 3 in (76 mm) in width for boxes having a gross

weight over 65 lb (30 kg) (grade above 200). The t ape sh all be cent ered onthe joint a nd exten d its full length, or within 3/8 in (10 mm) or full length be

centered on the joint and shall adhere over not less than 90% to the entire

area of cont act with the fiberboard .

St y l e s o f F i be r boa r d Boxes

The st yles covered in figures 2-6, 2-7, an d 2-8 are t he ba sic styles of domestic,

weath er-resistant , an d WWVR fiberboard boxes.

RSC, Regu lar S lo t t ed Box ( figur e 2-6)

In th is design, all the flaps (inner a nd outer) are of equal length. The outer

flaps meet in t he center wh en closed. This style is the m ost commonly used.

SFF , Spec ia l Fu l l F lap Slo t t ed Box ( figur e 2-6) In th is design the inn er flaps meet in th e center of the box. A one-fourth inch

gap is permitt ed.

FOL, Fu l l Over lap Slo t t e d Box ( figur e 2-6)

In this design, the length of the outer flaps shall be not less than the inside

width of the box minus 1 inch. This design results in a conta iner with at

least two thicknesses of fiberboard covering the entire top and bottom

surfaces.

OSC, Over lap Slo t t ed Box ( figur e 2-6)

In t his box, when closed, the inn er flaps must not overlap, an d th e outer flaps

will overlap the dista nce specified in th e order or invita tion for bids. The

inner flaps will be of the same length as the outer flaps, except when the

relation of width to length would cau se the inn er flaps to overlap. In su ch a

case, th e inner flaps will be cut t o meet in t he center of th e box.

CSSC, Cen ter Spec ia l S lo t t e d Box ( figur e 2-7)

This box is designed so that the inner and outer flaps meet in the center

giving a double thickness for top and bottom.

CSOSC, Cen ter Sp ec ia l Over lap Slo t t ed Box ( figur e 2-7)

This box is designed the same as the CSSC except the outer flaps are the

same length a s the inner flaps and ma y overlap. No flap cut ting is required.

HSCC, Ha l f S lo t t ed Box With Cover ( figur e 2-7) This box consist s of a box body an d a cover. The body is formed from

fiberboard, scored, slotted, and stitched to form a tube having four flaps of

equal length, approximately half the width of the box, on the bottom only.

Un less oth erwise specified the cover sha ll be a Type I. When sp ecified th e

cover sha ll be a Type II. The dept h of th e cover is 3 in. un less oth erwise

specified.




2-14

Figur e 2-6. Styles of fiberboar d boxes.




2-15





2-16





2-17





2-18

FP F, F i ve Pa ne l Fo l de r Box (f igu r e 2 -8 )

This design consists of a single scored slotted sheet. When set u p th e out er

end flaps will fully overlap. This box is used to an a dvant age in th e packing

of stacked or nested items which can be arr an ged on t he flat scored sh eet an d

when in position, the box is folded over th e cont ent s.

TSC, Ton gu e an d Slo t Closur e Box (f igu re 2-9)

This box is const ru cted of one piece fiberboard , scored an d slotted a s shown.

Slee ves (fig 2-11)

A sleeve may be specified for use with any of the box styles to provide added

stren gth. Sleeves will be made from class weath er-resistant fiberboard of th e

sam e type an d gra de as t he box. A sleeve will closely fit t he box over wh ich it

is placed and will cover th e top and bottom, and both end s. The length of the

sleeve (length of the stapled joint ) will be th e sam e as t he inside width of the

box. Un less oth erwise specified, th e corru gations will be at right an gles to

the score lines. If a but t joint is used it may be taped or th e overlap joint ma y

be stapled, stitched or glued. Alter na tively, th e location of th e body jointshall be in th e center of the top or bottom pan el, providing t he joint does not

interfere with t he r equired ma rking.

Line rs (Fig 2-12)

Liners a re ma de from one piece of fiberboar d. They ar e scored to cover the

end an d side panels of the boxes. The height of th e liners sh all be the full

inside depth of the boxes for which they are intended and the ends of the

liners shall be about in th e center of the side pa nels of the boxes.

Unless otherwise specified, liners for class domestic boxes shall be

constructed for double-wall fiberboard, grade 275. The joints shall be secured

with m inimu m 2 inch wide tap e conform ing to A-A-1492, A-A-1671. Liners

shall be constru cted from th e same class of mat erial as th e boxes th emselves.

Unless otherwise specified liners for class weather-resistant boxes shall be

cons tr uct ed of V15c fiberboar d. When s pecified gra de W5c, W6c, V3c, or V13c

sha ll be used. Liner s fabr icat ed from single-wall fiberboar d sha ll be A or C

flute and liners fabricated from double-wall fiberboard shall be any

combina tion of A, B, or C flut es, except BB flut es sha ll not be used . The

flut es sha ll be perpen dicular to th e box openin gs (as sh own in fig 2-12). The

joints sh all be secur ed with minimu m 2-inch wide tape r un ning n ot less th an

thr ee quart ers the length of the joint.




2-19

Figur e 2-10. Cover assemblies.

B OX MAKER 'S CERTIFICATE (F IG 2-13)

Each fiberboard box will be plainly marked with the box maker's certificate,

signifying compliance with the requirements of the applicable freight

classificat ion ru les. Type CF an d type SF, class domest ic boxes are not

required to be mar ked as being in compliance with ASTMs. There is no

objection to marking boxes that are manufactured in compliance with the

specification. Types CF a nd SF, class weath er-resistant boxes, in addition to

the box maker's name, will be marked with the date of manufacture

expressed in month an d year, su ch as 7-93; th e identification symbol, such a s

V3s; and the specification compliance data and the minimum average

burst ing strength gua ra nteed in excess of....PSI. The figure to be inserted

should be that corresponding to the dry mullen requirements in ASTM D

4727 for the part icular grade of fiberboar d used. For shipments to

Government agencies include the national stock number (NSN), inside

dimensions and outside cube marked below the specification data on allexterior boxes procur ed as an item of supply.




2-20

Figur e 2-11. Use of fiberboar d sleeve.

Figur e 2-12. Use of fiberboar d liner .




2-21

Figur e 2-13. Sam ple of box ma ker 's cert ificat e.

C lo s u r e R e q u i r e m e n t s

All boxes should be securely closed. Inn er an d outer flaps of slotted style

boxes should be drawn together as closely as possible to insure proper

closure. The length wise flaps should m eet on (RSC, CSSC, DSC) or overlap

on (OSC, CSOSC, FOL, SFF ), as specified. The flaps sh ould not pr oject over

the side or end edges, and th e application of adh esive or meta l stitches should

be such as to prevent lifting of free edges and corners of outer flaps on

assem bled boxes. ASTM D 1974, sta nd ar d pra ctice for meth ods of closing,

sealing, and reinforcing fiberboard shipping containers describes several

methods to close seal and reinforce solid and corrugated (excluding triple

wall) fiberboard .

Solid and corrugated fiberboard (excluding triple wall) boxes will use the

methods for closure, sealing, and reinforcing which are described in ASTM D

1974, Standard Practice for Methods of Closing, Sealing and Reinforcing

Fiberboar d Shipp ing Conta iner s. The ASTM lists, by box style, th e

appr opriate closur e meth od use of adhesives, tape, stitches/staples. For each

methods listed, details concerning the amount of adhesive required, or the

type and size of tape used, or the number pattern of stitches/staples for thatmet hods ar e ind icat ed. For exam ple, to close a 12" wide (inside width ) RSC

container for governmen t use, u sing stitches/staples, ASTM D 1974 indicat es

a closur e method 2D3 may be used. The staples must have a 1/2" crown an d

be evenly distributed where the inner and outer flaps overlay each other.

The number of 1/2" staples required to close the container is taken from the

ASTM D 1974 ta ble one referenced in th e 2D3 met hod. (See ta ble 2-7). The

left column of the ASTM D 1974 table indicates the inside width of the box -

in our exam ple 12". Read to the right from our box width u ntil it int ersects

with th e colum n for closur e meth od 2D3. Ten 1/2" staples or fasten ers ar e




2-22

required for each end of the box. The pat tern required for even distribut ion

per closure met hod 2D3 is indicat ed in figure 2-14. Figur es 2-15 thr ough 2-

19 provide examp les of th e closure met hods for fiberboar d boxes.

There are four methods of box sealing, Methods A through D (fig 2-19). They

are described in section 7 of ASTM D 1974. Within each sealing method, the

type of material authorized, its size, and its location on the box are specified.

Appl ica t ion of re in forcem en t (f igur e 2-20)

When only one band is required on a box in given direction, it shall be

centered except in the case of lengthwise bands on styles RSC and CSSC

boxes. On t hese styles the lengthwise band sh all be offset slightly from th e

seam formed by th e top and bottom flaps in th e closed position. When t wo or

more bands are used around the box in the same direction they shall divide

the box int o units of equal length. Cross banded boxes shall have th e longer

ban d applied first . Boxes carr ying loads having rest ricted point s of cont act

shall be banded, wherever pra cticable, over these points of contact. Bands

shall be applied straight an d shall be sufficiently tensioned. Metal bands

shall be embedded into the edges of the box, but shall not cut or tear the

fiberboard or crush th e contents. When a sleeve is specified the ban ds sha llbe applied after the sleeve is placed on the box.

Metallic an d nonmeta llic stra pping requirement s are listed in ta ble 2-8. The

required n umber of reinforcing ban ds ar e identified in t able 2-9.

Figur e 2-14. Closur e of class weat her -resista nt a nd WWVR fiberboard boxes with ad hesive

an d/or stitches.




2-23

Table 2-7 Nu mber of 2 in. Crown Sta ples or St itches for Regular Slotted Container s

Inside Width of

Box in A

Num ber of Fa sten ers a t Ea ch End of Box, by Method

2D1,

Commercial,Fig 5

2S2, Rule 41,

Fig. 6

2D3

Government, Fig7

6 2 2 6

7 2 4 6

9 4 6 6

10 4 6 8

11 4 6 8

12 4 8 10

14 6 10 12

16 6 10 14

17 6 12 14

18 6 12 16

19 8 14 16

20 8 14 18

22 8 16 20

24 10 16 22

A One in ch = 25.4 mm

Nu mber of Wide Crown Stap les or St itches for Regular Slotted Conta iners

Inside Width of

Box in A

Num ber of Fa sten ers a t Ea ch End of Box, by Method

2D4,

Commercial,

2D5, Old

Rule 41, Fig

2D6,

Government, Fig

8 1 1 4

10 2 2 5

12 2 2 6

14 2 2 8

16 2 4 9

18 2 4 10

20 2 4 11

22 3 5 12

24 3 5 14

26 3 5 15

A One in ch = 25.4 mm




2-24

Figur e 2-15. Closur e meth ods of fiberboar d boxes.




2-25

Figur e 2-16. Closur e meth ods for fiberboard boxes.




2-26

Figur e 2-17. Closur e meth ods for fiberboard boxes.




2-27





2-28





2-29

Table 2-8. Meta llic an d nonmet allic str app ing requ iremen ts. IAW ASTM D 4675.Gross weight of

container and contentsASTM D3953/ ASTM D4675

AS TM D3950 Non m et a lic B AS TM D38 53 Zin c Ga lve nize d

(Pounds) Type I Type II Type III Grade 1 Grade 2

Up t o 35 1/4 x 0.015

5/16 x 0.012

5/8 x 0.010

3/8 x 0.015

3/8 x 0.018

or 1/4 x 0.025

or

0.027

7/16 x 0.017

1/2 x 0.015

16-1/2 16-1/2

Over 35 t o 70, in cl. 3/8 x 0.015

A/

3/8 x 0.015

3/8 x 0.024

or

1/4 x 0.025

or

0.027

or

7/16 x0.025

7/16 x 0.017

1/2 x 0.015

16 15

Over 70 t o 110, in cl. 3/8 x 0.020

1/2 x 0.015

1/2 x 0.015

3/8 x 0.020

7/16 x 0.025

or

1/2 x 0.022

1/2 x 0.015

7/16 x 0.017

14 13

Over 110 t o 225 in cl. 1/2 x 0.020

5/8 x 0.015

1/2 x 0.020

5/8 x 0.015

7/16 x 0.025

7/16 x 0.023

1/2 x 0.020

13

A Size 1/4 by 0.015 in str ap m ay us ed for Type 1 loads an d FTC boxes of frozen foods.

B / Other t ype and sizes may be applicable.

Table 2-9. Required nu mber of rein forcing bands

Direction of bands1

Lengthwise Gir thwise Hor izontal2

Out side width of box Number of bands (min)3

Outside length of box

Number of bands(min)3

Ou t sid e d ep th of box N um be r of b an ds(min)3

Inches Inches Inches

Up to 9............................. None Up to 20 1 Up to 18 None

Over 9 to 18..................... 1 20 to 30, incl. 2 18 t o 30, incl. 1

Over 18 t o 30................... 2 Over 30 t o 48 3 Over 30 t o 48 2

Over 30 t o 48................... 3 Over 48 to 60 4

Over 48............................ Over 604 Over 484

1 Lengt hwise--Encircling top, bottom, and ends, Girth wise--En circling top, bottom, and sides. Horizonta l--En circling

sides and ends.

Note tha t the location of the openings determines t he designation of the panels, rath er tha n norma l storage position.

2 Horizonta l bands a re only occasionally required. where contents exert severe pressur e on vertical score lines, they

should be used.

3 Full telescope-style boxes, having corners not otherwise sealed to bodies, will usually require use of one or more

additional bands, both lengthwise and girthwise when dimensions approach the upper range of the size brackets listed

in above table. Additional bands, when required, will be specified by the pr ocuring a gency.4 As directed by the procuring agency.

NOTE

Reinforcement may be omitted from class weather-resistant boxes containing

non-perishable subsistence items and clothing which are to be palletized or

containerized An exception to this is nonperishable subsistence materiel

consigned to the Naval Supply Center at Norfolk and Oakland for subsequent

tran sfer at sea.




2-30

Figur e 2-20. Str app ing of fiberboar d boxes.




2-31

R e u s e a n d C o n s e r v a t i o n o f F i b e r b o a r d B o x e s

It is important that attention be given to the reuse and conservation of

fiberboar d boxes. This mu st be looked up on from an economical sta ndp oint .

If care is used in opening incoming fiberboard boxes, some of them may be

reused as interior intermediate containers, but never as exterior shipping

cont ain ers, with t he exception of good V-board boxes. The condition of th e

box is a big factor in its reus e. No box tha t ha s been cut, torn, pierced, ordama ged by water or moistur e should be reused. If used, V-board boxes are

included in th is cat egory, they may be reused for domestic shipment s. Used

boxes shall have all old markings pertaining to previous shipments

oblitera ted before reu se as int erior or exterior cont ain ers. If th e whole boxes

cannot be reused, consideration should be give to the use of clean, sound

fiberboar d a s ma ter ial for one of the following a pplicat ions:

Fa brication of blocking an d bra cing. Blocking an d bracing ar e used to

prevent movement of the item within the container, contact of items among

themselves (when more than one is packed in a shipping container), or

contact of an item with t he faces of the conta iner.

Fa brication of die-cut s, cells, tra ys, pads, et c., for cushioning pu rposes.Triple-wall Corr uga ted F iberboard Boxes (ASTM D 5168)

TRI P LE-WALL COR RU GATED FI BER BOARD BOXES (ASTM D 5168)

DESCRIP TION AND C HARACTERISTICS

A triple-wall corrugated fiberboard box is a container made of triple-wall

corr uga ted fiberboard in accorda nce with ASTM D 5168. Triple-wall

corrugated fiberboard consists of three corrugated sheets laminated to four

flat facings (fig. 2-3) resulting in a thick, relatively sturdy structural

mat erial. Boxes made of this mat erial have t he following char acteristics:

• They are especially suited for difficult, heavy loads that require

exceptionally large containers.

• They are extremely resistant to sudden forces such as those

encoun tered wh en th e box is dropped.

• They have a high resistance to compression and can sustain heavy

loads for long periods of time.

• They are lighter in weight and smaller in cube than wooden

conta iners ma de for the sam e items.

• They have certain inherent cushioning characteristics due to the

corr ugated st ock from wh ich th ey are ma de.

The fire-retar dan t requ irement s of boxes are inten ded to reduce losses due to

fire destruction.

Classes an d Styles. Triple-wall, corr uga ted fiberboar d boxes ar e fur nish ed in

th e following classes, styles, an d typ es of end s:

Nonweather resistant .

Weather resistant.

Fire-retardant.




2-32

Style A - One-piece fiberboard, five-pan el, with one of four types of ends , an d

with end s inser ted in box body (fig 2-21).

Style B - One-piece fiberboard , five-panel, with one of four types of ends , an d

with end s inser ted in box body overlapped on box ends (fig 2-21).

Style C - Two-piece fiberboard, three-panel, with one of four types of ends,an d with end s inser ted in box body overlap ped on th e box ends (fig 2-21).

Style D - Two-piece fiberboard, three-panel, with one of four types of ends,

and with en ds insert ed with outside edges of the box body overlapped on box

ends (fig 2-22).

Style E - A regular slotted fiberboard box conforming to style RSC ASTM D

5118. The body (man ufacturer's) joint should be 2 inches wide, crush ed, and

stapled on a slant n ot more than 1 inch ap art (fig 2-22). The corru gations of

that portion of the side panel in which the body joints overlap shall also be

cru shed. Style E boxes may also be mad e with a 1 1/2-inch crush ed overlap

on the t op and bottom pan el of the box. This is called an a lterna te st yle E box.

Style F - A full t elescopic fiberboard box, consistin g of a body an d a cover each

of one-piece slott ed an d scored t riple-wall fiberboard . The inside dept h of th e

cover sh all be t he overa ll depth of th e body (fig 2-22).

Style G - Ha lf regu lar slotted box with short top flaps a nd cover. Style G box

is similar to style F, except that all the top flaps are 4 inches long and are

crush ed-rolled 1 1/2-inches at th e edges. A cover, at least 6 inches deep,

forms the top of the cont ainer. The cover may be constr ucted so that t he end

and side flanges form a butt joint at each of the four corners (fig 2-23), or it

may be made with end or side flaps which are stapled to the adjacent flange

of th e top.

Wood End s

There are four types of wood or wood-cleated panel ends that can be used

with st yles A, B, C, an d D triple-wall, corru gate d fiberboar d boxes. The wood

used to fabricate the ends m ust conform to wood groups I a nd II as

set forth in PP P-B-621. The en ds ar e of th e following designs (fig 2-24).

Nu mber 1 end--A single piece of nomin al 2-inch lumber .

Number 2 end--Two thicknesses of nominal 1-inch lumber with the grain at

right angles, the two thicknesses securely joined by clinched nails, and no

piece less tha n 2 1/2 inches in width.

Number 3 end--Nominal 1-inch material with a nominal 1-inch thick cleatminim um width of 2 1/4 inches, securely joined by clinched n ailing.

Number 4 end--Cleated panel ends consisting of two sets of overlapped cleats

with a pan el of triple-wall corrugat ed fiberboard. The cleats sha ll be nominal

1-inch thick, 2 1/4 inches wide, and shall be assembled with clinched nailing.

The fiberboard shall be fastened to the inside of the cleats with either nails

or staples.




2-33

Figur e 2-21. Styles A, B an d C tr iple-wall corru gat ed fiberboard boxes.




2-34

Figur e 2-22. Styles D, E, an d F, triple-wall corr uga ted fiberboard boxes.




2-35

Figur e 2-23. Style G tr iple-wall corru gat ed fiberboard box.

Figure 2-24. Types of ends to be used with styles A through D triple-wall corrugated fiberboard

boxes.




2-36

Li m i t a t i ons

Maximum weight and size limitations for triple-wall corrugated fiberboard

boxes ar e not given in ASTM D 5168. When tr iple-wall, corr uga ted

fiberboard boxes are to be used for commodities covered in Rule 41 of the

Uniform Freight Classification and item 222 of the National Motor Freight

Classification, the su m of the inside length, width , and depth shall not exceed

125 inches. Conta iners exceeding th ese limitations must be made un der aspecial package per mit.

Sea l i ng

When sealing against the entry of water or dust is required, all seams and

joints of the boxes shall be covered with minimum 2-inch tape conforming to

ASTM D 5486, Type V. Closur e of slotted boxes is frequ ent ly done pr ior t o

sealing.

Cl os u r e

The kinds of closure for triple-wall, corrugated fiberboard boxes will depend

on the style of box to be used, and may be made by means of nails, staples,

steel straps, filament-reinforced tape, or a combination of these materials.

When nails are used for closure or for fastening blocking and bracingmembers t o the inter ior of the boxes, it is recommen ded th at each na il should

pass through an oversize washer, piece of banding, or clips designed to

prevent pu lling of th e nail heads thr ough the triple-wall mat erial. Whenever

rein forcing needed , DOD personn el may u se ASTM D 3950, ASTM D 3953, or

ASTM D 4675.

Closur e of s ty le A boxes

This style may be closed with zinc-coated or copper-washed staples, with

divergent points an d minimu m dimen sions of 14 gauge wire, 3/4 inch crown,

and 1 1/4 inch legs; with flat, Type I, Class A or B, 5/8 inch wide and 0.018

inch thick steel straps conforming to ASTM D 3953 or with nonmetal

strapping in accordance with ASTM D 3950, Type I or II (when Type I is used

it shall be Grade B) with a nominal width of 5/8 inch; or with pressure-

sensitive, filament-reinforced tape meeting the requirements of ASTM D

5330, Type III, 1/2-inch wide, except for Styles E and F, which shall be 1 inch

wide. On weat her-resistan t boxes, the ASTM D 5330 tape sh all be Type IV,

3/4 inch wide, except for Styles E a nd F , which sha ll be 1 inch wide.

Using n a i l s for c losur e of s ty le A boxes

When nails or staples are used, they shall be spaced not more than 2 inches

apar t an d staggered as permitt ed by the th ickness of the ends of the box. The

nails or staples shall extend through each thickness of fiberboard and into

th e wood ends. If th e box is 24 inches long, a st rip of filamen t-reinforced tape

shall be placed at the center of the outside top flap so as to extend onto the

top flap 5 inches and onto the side panel 5 inches. For length great er th an 24inches, one such strip will be added for each additional 18 inch increment of

length greater t han 24 inches. The total number of strips will be spaced

even ly (fig 2-25).

Us i ng s t r ap s f or c lo s u r e o f s t y le A boxes

When steel or nonmetal straps are used, one band will be placed at each end

of th e box to encircle th e top, sides, an d bottom of th e box. The st ra ps will be

placed not more than 3 inches in from the ends to bear evenly on the wood

ends. If the box is 24 inches long, a stra p will be added at the center.




2-37

Filament -reinforced tape may be used in lieu of th is additional str ap. For

lengths greater than 24 inches, one such strap will be added for each

additional 18 inches of length an d placed so that th ey are evenly spaced (fig

2-25).

Us i ng Tap e Fo r C l os u r e Of St y l e A Boxes

When filament-reinforced tape is used, a 10-inch strip will be placed 2 inchesin from each end of th e box. For boxes 24 inches long an over, additiona l

strip requiremen t ar e the same as for steel strapping. All the tape strips will

be applied perpendicular to the joint formed by the top flap a nd t he side wall

of th e box. They will be cent ered over th e joint a nd exten d 5 inches onto th e

top flap an d 5 inches on t he side wa ll (fig 2-25).

Closur e Of Sty le B Boxes

Style B boxes may be closed with nails or staples in the same manner as

Style A boxes; but, in addition, a staggered row of nails or staples, spaced not

more than 2 inches apart, must be driven through the overlap portion of the

top flap into the face of the wood ends. When u sing steel straps or filamen t-

reinforced tape for closure, the same requirements as given for Style A boxes

also apply to Style B (fig 2-25).

Closur e of S ty le C Boxes

This style of box will be closed along the top and sides by means of nails,

staples, or steel straps as specified for Style A boxes, except when using nails

or staples they will be spaced not more than 2 inches apart and staggered

and driven th rough t he t op one-half of the box into th e wooden en ds along the

two end edges of each side panel and both end edges of the top panel (fig 2-

26).

Closur e of S ty le D Boxes

This style of box shall be closed along the top and sides by means of nails,

sta ples, or steel str aps a s specified for style A. In ad dition, a stagger ed row of

nails or staples sha ll be driven t hrough th e overlapping top flaps in to the face

of th e wooden ends. For boxes 24 inches long and longer, str ips of ta pe will

be applied as for style A box (fig 2-26).

Closur e of S ty le E Boxes

Style E boxes may be closed by the use of staples, steel or nonmetallic

stra pping, or with t ape.

C lo s u r e w i t h S t a p le s

Staples will not be used for boxes fabricated with class weather-resistant

fiberboard. Stap les are placed not more than 1 1/2 inches, or less tha n 1 inch,

from the free edge of th e flap. Spa cing ar ound t he edge of each flap is not

more tha n 5 inches, center -to-center of the st aples. Additiona l staples are sospaced with in th e boun dar ies outlined by the edge sta ples so tha t n o area will

have a diameter greater than 4 inches without a staple, with a minimum

nu mber of eight st aples in each flap. Sta ples are flat wire, 0.050 inch th ick,

0.085 inch wide, with a 1 1/4-inch crown (fig 2-27).




2-38

Figur e 2-25. Closur e of styles A an d B, tr iple-wall corru gat ed

fiberboar d boxes.




2-39

Figur e 2-26. Closur e of styles C an d D, tr iple-wall corru gate d

fiberboar d boxes.




2-40

Cl os u r e Wi t h M e t a l o r Nonm e t a l li c S t r a pp i n g

The requirem ents for closur e with str apping is th e sam e as for style A boxes,

except th at a lengthwise stra p may be applied to hold the girthwise stra p flat

(fig 2-27).

Cl os u r e Wi t h Tap eA 12-inch strip is applied to each end of the two top and bottom flaps so that

6 inches of each strip is attached to the flap and 6 inches of each strip is

att ached the end pan el. The strips are located adjacent to the inner length

edge of th e flaps, appr oxima tely 2 inches from th is edge. The use of

add itional st rips will be specified for style A boxes.

Cl os u r e o f S t y le F Boxes

This style may be closed with steel or nonmetallic straps or filament-

reinforced tape. When str aps a re used, th ey will be applied as described for

style E boxes. When ta pe is used, one str ip will be used on each side and

each end. The str ips will be not less than 12 inches long and will be applied

at t he center of th e side and end pa nels and exten d to the bottom of the box.

When t he length of th e box is 24 inches, an additional strip will be added toeach side and the two will be evenly spaced. Additional strips a s requ ired for

length will be added to the ends wh en t he box is 24 inches or great er in width

(fig 2-28).

Closur e of S ty le G Boxes

When this box is used in conjunction with a pallet, closure and sealing will be

as specified by the procur ing activity. Without a pa llet, an additional strip

will be added to each side an d th e box will be closed with str aps. One st rap

will be centr ally located a round the top, ends, and bottom. Two straps will be

applied around the top, sides, and bottom, at a distance from the ends equal

to thr ee-four ths th e length of th e inn er flaps. If th e distan ce between the

straps exceeds 24 inches, additional straps will be spaced not more than 24

inches a par t (fig 2-29).

P a p e r b o a r d B o x es

Paper boar d boxes are mainly used for inter ior pa cking. They are a vailable in

various types, styles, and sizes, and must conform to requiremen ts of PPP -B-

566, and PP P-B-676. In man y instan ces, depending upon the item, a

paperboard box may be used in packing when u tilizing par cel post. For

fur th er det ails on pa perboard boxes, see FM 38-700.




2-41

Figur e 2-27. Closur e of style E, tr iple-wall fiberboard box.




2-42

Figur e 2-28. Closur e of style F, tr iple-wall fiberboard box.




2-43

Figur e 2-29. Closur e of G style triple-wall fiberboard box.




3-1

CHAPTER 3

WOODEN CONTAINERS AND PALLETSCONTAINER MATER IALS

WOOD AS A CONTAINER MATERIAL

Wood is particularly valuable as a container material because of its high

stren gth-weight ra tio which compares favora bly with mild steel. Tests and

experience have shown that the strength of a wooden container depends

largely upon th e type of wood used in its const ru ction. The du ra bility of wood

and its ability to withstand shock and impact stresses are important

properties in the selection of wood for containers. Military Handbook MIL-

HDBK-7, "Lumber and Allied Products", provides a ready source of

information on wood products normally procured in considerable quantity for

Depart ment of Defense installations. This handbook is not intended forreference in purchase specifications or other contractual documents.

However, it will assist mat erially with installation r equisitioning, receiving,

inspection, stora ge, an d ha ndling of cont ain er wood ma ter ials. Also see

ASTM D 6436, Quality of Wood Members for Cont ain ers a nd P allets.

Wood Gr oup s

All woods fall into two gener al categories: Eith er softwoods, which come from

coniferous or needle-bearing trees; or hardwoods, which come from broad-

leafed trees. For pu rp oses of cont ainer const ru ction, wood is divided int o four

groups based on nail holding power, tendency to split, comparative strength

as a beam , and shock resisting capacity (fig 3-1). Over 90 percent of all

wooden containers are made from Group I and II woods however, the

materials given in Section 3 of the applicable container specification must be

used. When a wood group is specified in t he cont ract, an y species in t ha t

group ma y be selected.

G r o u p I includes the softer woods such as white fir, ponderosa pine, yellow

poplar, cottonwood, cedar, an d oth ers. These woods ar e relatively free from

splitting when being nailed, have a moderate nail-holding power, moderate

stren gth as a beam, an d moderate shock resisting capacity.

G r o u p I I includes the harder soft woods such as Douglas fir, southern pine,

hemlock, and larch. They have great er nail-holding power tha n th e Group I

woods, as well as greater st rength an d shock resisting capa city. Group II

woods are more inclined to split, the grain often deflects nails and causesthem to run out at the side of the piece.

G r o u p I I I includes the medium density har dwoods. Ash, elm, an d cherr y

are exam ples. These are similar t o Group II woods in n ail-holding power an d

strength a s a beam, but have less tendency to split and sh atter under impact.




3-2

Figur e 3-1. Cha ra cteristics for the classificat ions of wood.

G r o u p I V includes th e tru e har dwoods such as oak, har d maple, and h ickory.

These woods have the greatest shock resistance and nail-holding power, are

extremely strong, but ar e very susceptible to splitting. They are t he hea viest

and ha rdest woods, an d ar e difficult to work.

Wood Defec t s

All boards should be cut t o the correct length an d be free from a ll defects t ha t

materially weaken them, expose the contents of the box to damage, or

inter fere with t he pr escribed fabr icat ion or n ailing (fig 3-2).

Knot s . Knots in wood are most weaken ing when located in the m iddle third

of the length of the board. Across the width of th e board , the weaken ing

effect is proportional to the effective diameter of the knots, measured as

shown in fig 3-3. No knot, or series of kn ots across the face of the board ,

within a length equal to the width of the board, shall have a diameter or sum

of diameter s great er tha n one third th e width of the board. No knot will

exceed 4 inches when m easur ed across the width of th e board .

Slope o f g r a i n . Any board with a slope of grain st eeper th an a r atio of 1 in

10 of length is not perm issible. Figur e 3-2 shows the resu lts of excessive

slope or cross gra in.

M oi s t u r e C o n t e n t

It is importan t th at t he moisture conten t of lumber requ ired by an applicable

cont aine r specification be followed. High moistu re cont ent in lum ber will

cause excessive tar e weight. Shr inkage, due to the loss of high moisture

content in the boards of a nailed wood box will cause gaps between the pieces

of lumber. Shrinkage will also cause the loss of nail holding-power, splitting

of the lum ber at t he na ils, and th e loosening of stra ps. Moisture cont ent is

determ ined by the u se of electric moistur e meter s or by th e oven dr y meth od,

as out lined in ASTM D 2016.




3-3

M ois t u r e Me t e r M e t h od

The moisture meter method is faster than the oven dry method, but less

accura te. A moistur e met er consists essentia lly of an electrical device

designed to measure the resistance or the capacitance of the wood between

two electrodes in conta ct with t he sam ple. The values obtained will vary with

the wa ter cont ent of th e wood. They will also vary as a result of a n umber of

other factors, most important of which are they temperature of the wood, itsspecies, and density. Although correction tables are furnished with each

instrument which must be used for even approximations of true values, the

readings obtained are still only appr oximations because th e effect of th e other

variables cannot be determined with scientific accuracy. Instruments of this

type can not be used where a n a ccur acy of plus or minu s 1 percent is required.

In view of this, the moisture m eter m ethod is primar ily usable for screening

inspections of large lots of lumber, while the oven dry method is almost

always resorted to in th e event of disputes. The meter used should be

capable of giving instantaneous readings of moisture content within a range

of 7 to 20 percent, and should be equipped with correction tables to permit

the correction of meter readings for temperature, species, and density. The

meter should be adjusted prior to use in accordance with the manufacturer's

instru ctions. When a series of readings are being made, the adjustm ent

should be checked periodically. Batt eries should be replaced whenever initial

adjustm ent can not be accomplished, or whenever it is obvious t ha t ina ccur ate

readings a re being obtained because of weak ba tter ies. The following general

precautions sh ould be observed:

Figur e 3-2. Wood defects.




3-5

O v e n D r y M e t h o d

Use a dr ying oven capable of mainta ining a consta nt temper atu re of 212oF. to

221oF., and a scale that is acura te to within one-half of 1 percent. To

determ ine th e moisutre content, u se th e following procedure:

• Cut off a least the first 12 inches of the piece in order to avoid the

effects of end d rying.• As soon as possible, cut off a piece approximately 1 inch the full

thickness by the full width of the piece.

• Immediately after sawing, remove all loose splinters and determine

W, the weight before drying.

• Place th e wood in the h ot oven and leave overnight. The next day,

weigh the specimen and replace in the oven. Repeat at 2-hour

intervals until the weight is the same at the end of two successive 2-

hour periods. This will occur after approximat ely 24 hour s. If more

than one, specimen must be open-piled in the oven to allow free

access of air to all pa rt s of th e pieces.

• The final weight of the piece immediately after removal from the oven

is D, the oven dr y weight.

• Calculate the percentage of moisture content by using the following

formula:

(W-D)

_____X100=% Moisture

W

OT H E R MATERIAL SKIDS USED IN C ONTAINER C ONSTRUCTION

The following additional materials are used in container construction as

applicable.

Na ils (ASTM F 1667-95)

These may be box, corker, sinker, cooler, or common nails. Sinker and cooler

nails are relatively slender, can be driven into denser woods and withstand

shocks well. The h eads do not brea k off or pull thr ough th e wood easily (fig

3-4). The resistan ce of na ils to withd rawa l varies with a n umber of factors

such as the hardness or density of the wood, surface condition of the nails

and t he shape an d form of na ils. Dense woods hold nails much better th an

soft woods. To get th e same na il str engt h with softer woods, more na ils or

larger na ils are r equired. The use of chemically etched or coated n ails is

part icularly importa nt with soft woods. Resistance of na ils to withdr awal

also varies with the area of contact of the nail with the wood, increasing

directly with the diameter of th e nail an d the depth of penetr ation. Nails

may be subjected to forces which withdraw them directly, that is, in the

direction of th eir length, or to forces which displace th em later ally. Na ils

offer greater resistance to lateral displacement than to direct withdrawal.Cement coating or etching increases the resistance of nails in direct

withdrawal more than in lateral withdrawal, since the nail shank is distorted

in lateral withdrawal about the same, whether coated or uncoated. Etched

nail sur faces ha ve certa in adva nta ges over cement coated surfaces. The effect

of etching in increasing withdr awal r esistance is relatively perma nen t, while

cement coatings deteriorate a few months after nailing. Etched nails are

effective with woods of all densities, while cement coatings tend to rub off

when n ails are driven into dense woods. Here is a simple procedur e for

etching na ils. Pr epar e a 10 percent solution (by weight) of comm ercial

monoammonium phosphate in water . Do not use meta l conta iner for

prepar ing or storing the solution. Keep the solution nea r room temper atu re

(about 68o). Immer se the nails in th e solution for about 7 hours, stirring




3-6

occasiona lly. Five gallons of solution is sufficient to etch a bout 100 poun ds of

nails and rinse with wat er. Fina lly, airdry the na ils to prevent ru sting.

Screws (FF-S-111) Sometimes it is particularly desirable to use screws for

closing wooden boxes when the contents are such that they need to be

checked, lubricated, or inspected.

Cor r uga t ed Fa s t ene r s (FF -F-133)Corrugated fasteners are used in the construction of built-up faceboards in

wooden boxes (figure 3-11). When u sed for this pur pose, na iling ma chine

opera tors do not have to align each board prior to nailing. Corru gated

fasteners also help to prevent pilferage of contents during storage or

shipment.

.

Figur e 3-4. Na ils.




3-7

Sta ple (ASTM F 1667)

Staples are used to atta ch cleats to panels on cleated-panel boxes. Stap les

with crowns not less than one-ha lf inch must be long enough to penetr ate t he

thickness of both the panel material and the cleat with a minimum clinch of

one-eighth of an inch.

Wi r e F a s t e n e r s

Fasteners, other than nails, and staples, may be used to attach cleats toplywood or veneer pa nels. They must pr ovide later al displacement equa l to

tha t of na ils properly spaced an d driven. Wire fasten ers are form ed and

driven by ma chine from a roll of knu rled wire.

S t r a p p i n g

Either flat metal or round wire conforming to ASTM D 3953, ASTM D 4675,

and ASTM D 3950, to strap wooden cont ainers.

P lyw ood (A-A-55057)

Plywood used for boxes, either for domestic or oversea destinations, shall be

as specified in th e procur ement docum ent or other directive establishing th e

container requirements. Plywood will be purchased in accordance with A-A-

55057.

Fiberboard (ASTM-D-4727)

For oversea cleated pan el boxes, solid V-board with a minimum dry bur sting

stren gth of 400 pounds is th e only mater ial au thorized. For domestic cleated

panel boxes, either solid fiberboard, solid pulp-board, or double-faced

corrugat ed boar d may be used.

P a p e r O v e r l a i d Ve n e e r

This material, made of thin veneer covered on both faces with heavy kraft

paper, is used as panelling material for paper overlaid veneer boxes,

conforming to PP P-B-576.

NAILED AND LOCK-COR NER WOOD BOXES (P P P -B-621)

DESCRIP TION AND SELECTION

The nailed wood box is constructed of wood, assembled by fastening the top,

sides, and bottom to the ends with nails, or by gluing the lock-corners of the

sides an d ends and fasten ing them to the top and bottom with nails. The

placement of cleats on the ends or the lack of cleats determines the style of

box. Na iled wood boxes will not be u sed if fiberboard or less expen sive light -

weight boxes will provide ad equat e protection for shipment and storage.

C HARACTERISTICS

Nailed wood boxes are satisfactory shipping containers for supplies and

equipment, especially for items that ar e susceptible to dam age. Thesecontainers ha ve th e following favorable an d u nfavora ble cha racteristics.

• Favorable char acteristics.

ο Maximum protection to contents a gainst dam age due to punctur e,

distortion, and brea kage.

ο Ability to support loads due to stacking during transit and

storage.




3-8

ο Ability to contain difficult loads without undue distortion.

ο Adapt ability to complex wood blocking an d bra cing.

ο Adaptability to varying strengths by adjusting the style of box,

thickness of materials, and group of wood.

ο Easy workability an d simple constr uction.

• Unfavorable char acteristics.

ο High tar e weight an d cube.

ο Not watertight.

ο Tendency to crack.

Cl as s an d Gr ad es ( F i g 3-5 )

The classes of na iled wood boxes ar e--

• Class 1, dom estic boxes. These boxes are subject to storage,

rehandling, or shipment to domestic destinations in which no sea

tra nsporta tion is involved. Net weight is limited to a m aximum of 600

poun ds (see tables 3-1 and 3-2).

•

Class 2, oversea boxes. These boxes are subject to storage,reha ndling, or reshipment to offshore and oversea destinat ions. Net

weight is limited to a ma ximum of 1,000 poun ds. Class 2 boxes (all

styles) sha ll be fur nish ed in the following grad es, as specified. When

no grade is specified in the contract, purchase order, or other

procur ement documen t, Grad e B sha ll be supplied (see ta bles 3-3 and

3-4).

ο Grad e A--With pr eservative treatm ent.

ο Grade B--Without preservative treatment.

St y l e s an d L i m i t a t i ons

Class 1 and 2 boxes are described simultaneously, as applicable, in the

covera ge of th e box styles. Styles 1, 2, 2 1/2, 4, 4 1/2, 5, 6, and 7 ar e perm itted

for Class 1 (domestic) and Styles 2, 2 1/2, 4, 4 1/2, 5, and 7 are permitted forClass 2 (oversea ) shipm ent s. Weight limita tions for each class, as applicable,

ar e given un der t he des cription of each st yle of box.

St yle 1 Bo x (fig 3-6)

Style 1 box is ident ified by lack of cleat s on th e end faceboar ds a nd single line

na iling of sides to ends, and of top an d bott om to ends a nd sides. Style 1 box

is inten ded for domestic shipment s only. It is restricted to Type 1 an d 2

loads . Style 1 box may n ot exceed a load limit of 50 poun ds for t wo-piece

sides an d 100 poun ds for one-piece sides. Direction of th e grain on St yle 1

box must r un in th e direction of the gr eatest dimension. This box is limited

to a height of 10 inches a nd t otal dimensions (length, width, a nd d epth) of 50

inches.




3-9

Figur e 3-5. Classes of na iled wood boxes.


Style 2 box is identified by two vertical and two horizontal cleats on each end.Vertical cleats are positioned at right an gles to the grain of the en d. They

are one-eighth of an inch shorter than the edge of the end at the top and

bottom. Horizont al cleats, which ar e placed para llel to th e grain of end, are

butt -joined to th e vertical cleats a nd a re flush with th e top and bottom edges

of the box. The top, bottom, an d sides extend over th e ends an d cleats an d

are na iled in a staggered patt ern. Thus, ther e is some side-grain na iling on

all edges. The cleat pat ter n provides ease of ha nd ling. Weight limita tion for

Style 2, Class 1 box (domestic) is 600 poun ds. Weight limitat ion for Style 2,

Class 2 (oversea) box is 1,000 poun ds.




3-10

Figur e 3-6. Styles of na iled woods boxes.

St yle 2 1/2 Box (fig. 3-6)

Style 2 1/2 box is identified by two vertical notched cleats and two horizontal

cleats on each end. It has th e same advanta ges as the Style 2 box but is

slightly higher in cost. Vertical cleat s are notched appr oximat ely one-fourt h

to three-eighth s inch to support the horizont al cleats. Vertical cleats are

positioned one-eight h inch above th e bottom edge of th e end. Weight

limitat ion for St yle 2 1/2, Class 1 box (domestic) is 600 poun ds. Weight

limitat ion for St yle 2 1/2, Class 2 box (oversea ) is 1,000 poun ds.


Style 4 box is ident ified by two vertical cleats on ea ch end. Vertical cleats ,

which are positioned at right angles to the grain of the end, are one-eighth

inch shorter th an t he outside surfaces of the t op and bottom of the box. The

top and bottom cover th e sides. They fit between the cleats a nd a re at tached

to the ends by stra ightline, side-grain n ailing. The sides overlap the ends

and cleats, providing for a staggered na iling patt ern. Weight limitation for

Style 4, Class 1 box (domestic) is 250 pounds. Weight limitation for Style 4,

Class 2 box (oversea ) is 400 pounds.




3-11

St yle 4 1/2 Box (fig 3-7)

Style 4 1/2 box is identified by two horizont al end cleats. Horizonta l cleats ,

which are positioned at right angles to the grain of the end, are one-eighth

inch short er tha n th e out side surface of the sides. The sides extend over th e

ends, and p rovide for str aight-line, side-grain n ailing. The top and bottom

extend over the ends and cleats, an provide for both side- and end-grain

na iling. Weight limitat ions for both class es of boxes ar e the sa me as for Style

4 boxes.


Style 5 box is identified by interior vertical cleats. The cleats extend to within

one-eight inch from the top and bottom edges of th e end of th e box. Oth er

than the placement of cleats, construction and nailing pattern for this

container is the same as for Style 4 box. The interior cleats may be

rectangular or triangular, provided the cross section area of the triangular

cleat is not less tha n th at of th e required rectangular cleat. Weight limitation

for St yle 5, Class 1 box (domestic) is 250 pound s. Weight limita tion for St yle

5, Class 2 box (oversea ) is 400 pounds.


Style 6 box is identified by th e lockcorner const ru ction wh ich is glued. This

box has about th e same advan tages an d disadvanta ges as Style 1 box. Style 6

box is int end ed for domest ic shipm ent s only and Type 1 and 2 loads . This box

has a weight limitation of 50 poun ds, but m ay go to 100 pounds if the box has

one-piece sides.


Style 7 box is an internally reinforced box consisting of a skidded base with a

separate hood assembled from the top, sides and ends. Style 7 boxes are for

contents ra nging from 100 to 1,000 poun ds. The contents mu st readily

permit at tachmen t to the skids. The base is assembled to 2 X 4 inch skids to

facilitat e moun ting to a skid base. The skids are positioned across the

extreme ends of the bottom pieces to permit attachment of all end pieces tothe skid edges. Vertical and horizontal framing members and reinforcing

members in the form of a rectangle, and cross diagonals, as applicable, are

att ached to th e int erior surfaces of the prefabricated box pan els. Fra ming

members a re requ ired when cont ents exceeds 250 poun ds or when side length

is greater t han end length.

End panels are identified by vertical sheathing which extends within one-

eighth of an in ch of each skid bottom. The hood assembly is placed over th e

item mounted to the base, then na iling and stra pping is accomplished. Style

7 boxes are int ended for both Class 1 a nd Class 2 u se.

Sh a l low Box (f ig 3-9)

When t he inside dept h of a box is five inches or less, cleats a re not u sed. If cleats were applied to shallow boxes, they would be so small tha t in at taching

them to the ends th ey would split. The end of th e box may be made of one

piece, or if the end is approximately square, it may be made of two pieces

placed so th at t he gra in ru ns in opposite directions. For Style 2, 2 1/2, 3, 4,

and 4 1/2 boxes, the th ickness of the ends sh all be not less th an th e combined

thickness of the en d and cleat, as specified. Slides overlap th e ends. Top an d

bottom overlap th e sides an d ends. Top, bottom, and sides are a tta ched to the

ends by sta ggered nailing. Weight limita tion is 1,000 poun ds for oversea

shipments.




3-12

Cons t r uc t i on De t a i l s

When nailed wood boxes are built locally, use the following information for

constru cting and closing the various styles. If pur cha sed and r eceived in

shook form, the sides, top, an bottom will be ready to be attached to the

constru cted ends. Figure 3-10 shows the amoun t of acceptable splitting

allowed in th e component par ts.

Figur e 3-7. Styles of na iled wood boxes.




3-13

Figur e 3-8. Style 7 nailed wood box.

Figur e 3-9. Sh allow boxes.




3-14

Size of lum ber

The size of lumber used in nail wood box construction is found in tables 3-1,

3-2, 3-3, an d 3-4. Informa tion necessar y to use th ese tables is: Class of box,

type of load, n et weigh t, st yle of box, an d group of wood.

Figure 3-10. Split boar d ru les




3-15

Cons t r uc t i on Of Bu i l t -Up F aceboa r d P i ece s (F i g 3 -11)

The number of pieces in any side, top, bottom, or end will be chosen so that

no single solid piece or built-up piece shall be less than 2 1/2 inches in width

measu red across the face, an d will not exceed th e nu mber given in t able 3-5.

Built-up face-board pieces may be constructed according to the following

conditions:

• The Linderma n joint when glued.• Butt joints glued under pressure.

• Tongued a nd gr ooved joints glued und er pr essure.

• Tongued and grooved joints glued with two or more corrugated

fasteners d riven from one side.

• Tongued and grooved unglued joints with two or more corrugated

fasteners dr iven from alter na te sides.

Figur e 3-11. J oined pieces of lum ber.




3-16

Table 3-1. Boxes for domest ic shipment , type 1 (easy) and t ype 2 (average) loads; thickness of sides, tops, bott oms, and en ds, and thickness

and widt h of cleats.

Weight of content sSt yle of Box6

Groups I an d II woods1 Groups III and I V woods2

Exceed-ing

Notexceeding

Thicknessof sides,tops, andbottoms

Thickness of ends

Thicknessand widthof cleats

Thicknessof sides,tops, andbottoms

Thicknessof ends

Thickness andwidth of cleats3

Pounds Pounds Inch Inch Inches Inch Inch Inches-- 50 1 3/8 1/2 -- 1/4 1/2 --

-- 50 4,4-1/2,5 3/8 1/2 1/2 by 2 1/4 1/2 1/2 by 1-3/4

-- 50 2 3/8 3/8 3/8 by 2 1/4 3/8 3/8 by 1-3/4

-- 50 6 3/8 1/2 -- 1/4 3/8 --

50 100 14 3/8 1 -- 3/8 3/4 --

50 100 4,4-1/2,5 3/8 5/8 5/8 by 3 3/8 1/2 1/2 by 1-3/4

50 100 2,2-1/2 3/8 1/2 1/2 by 2 3/8 1/2 1/2 by 1-3/4

50 100 64 3/8 1 -- 3/8 1/2 --

100 250 4,4-1/2,5 1/2 5/8 5/8 by 3 1/2 1/2 1/2 by 2-1/4

100 250 2, 2-1/2,7 1/2 5/8 5/8 by 3 1/2 1/2 1/2 by 1-3/4

250 4005 2, 2-1/2,7 5/8 1 1 by 3 1/2 3/4 3/4 by 2-1/4

1Nominal. The dressed sizes of wood shall equal or exceed the m inimum sizes shown in Table I of 20-70. For th e purpose of this

specification, reference to STD 20-70 shall be limited to th e above.2Thickness toleran ce shall be " 1/16 inch for par ts 3/8 inch thick an d thicker, except as other wise specified. Thickness t olerance shall be +

1/16 - 1/32 inch for pieces less t han 3/8 inch t hick.3Width t olerance shall be " 1/16 inch, except a s other wise specified.4Providing the boxes have one-piece solid sides of sawed lumber a nd conten ts a re packed in inter ior container s.5When load t o be carried by th e box exceeds 400 pounds, u se Table 3-3; when load exceeds 600 pounds, us e Table 3-4.6Styles 2, 2-1/2, 4, 4-1/2 boxes. Unless oth erwise specified, when t he inside dept h of a box is 5 inches or less, end cleat s sha ll not be used.

Thickness of th e ends shall be not less tha n the combined thickness of the end an d cleat , as specified. Each side and end sha ll be mad e

from one piece, except when the end is approximately square, a two-piece end may be used with each end piece of approximately equal

thickness, and with t he grain of each piece runn ing at right angles to the other. Two-piece ends shall be nailed together with at least two

clinched na ils.

Table 3-2. Boxes for domest ic shipment , type 3 (difficult) loads; thickness of sides, top, bottoms, an d ends, an d th ickness and widt h of

cleats.

Weight of content sSt yle of Box5


Exceed-

in g

Not

exceeding

Thickness of

sides, tops,and bottoms

Thick-

ness of ends

Thickness

and widthof cleats

Thickness

of sides,tops, andbottoms

Thickness

of ends

Thickness a nd

width of cleats

3

Pounds Pounds Inch Inch Inches Inch Inch Inches

- 50 4,4-1/2,5 3/8 5/8 5/8 by 2 3/8 1/2 1/2 by 1-3/4

50 100 4,4-1/2,5 1/2 1 1 by 3 1/2 1/2 1/2 by 1-3/4

50 100 2,2-1/2 1/2 5/8 5/8 by 2 1/2 1/2 1/2 by 1-3/4

100 250 4,4-1/2,5 5/8 1 1 by 3 1/2 3/4 3/4 by 2-1/4

100 250 2,2-1/2,7 5/8 1 1 by 3 1/2 1/2 1/2 by 2-1/4

250 400 2,2-1/2,7 1 1 1-1/4 by 4 3/4 3/4 3/4 by 2-1/4

400 6004 2,2-1/2,7 1 1 1-1/4 by 4 3/4 3/4 3/4 by 2-5/8

1Nominal. The dressed sized of the wood shall equa l or exceed the m inimum sizes shown in Table I of STD 20-70. For th e purpose of thisspecification, reference to STD 20-70 shall be limited to th e above.2 Thickness t olerance shall be " 1/16 inch, for part s 3/8 inch thick and t hicker un less otherwise specified.3Width t olerance shall be " 1/16 inch, unless other wise specified.4When load t o be carried by th e box exceeds 600 pounds , use Table 3-4.5Styles 2, 2-1/2, 4, 4-1/2 boxes. Unless oth erwise specified, when t he inside dept h of a box is 5 inches or less, end cleat s sha ll not be used.

Thickness of th e ends shall be not less tha n the combined thickness of the end an d cleat , as specified. Each side and end sha ll be mad e

from one piece, except when the end is approximately square, a two-piece end may be used with each end piece of approximately equal

thickness, and with t he grain of each piece runn ing at right angles to the other. Two-piece ends shall be nailed together with at least two

clinched na ils.




3-17

Table 3-3. Boxes for overseas shipm ent , type 1(easy) and type 2 (average) load; thickness of sides, tops, bottoms, an d ends, and t hickness

and widt h of cleats.

Weight of content s

Style of box1


Exceed-

ing

Not

exceed-

in g

Thickness of

sides, tops,

and bottoms

2/

Thickness

of ends 2/

Thickness

and width of

cleats 2/

Thick-ness of

sides, tops,

and bottoms

Thickness of

ends

Thickness

and width of

cleats 4/


-- 50 4,4-1/2,5 3/8 5/8 5/8 by 2 3/8 1/2 1/2 by 1-3/4

50 100 4,4-1/2,5,7 1/2 1 1 by 3 3/8 1/2 1/2 by 1-3/4

100 250 4,4-1/2,5 5/8 1 1 by 3 1/2 3/4 3/4 by 2-1/4

100 250 2,2-1/2,7 5/8 5/8 5/8 by 3 1/2 1/2 1/2 by 2-1/4

250 400 4,4-1/2,5 1 1 1 by 3 3/4 3/4 3/4 by 2-1/4

250 400 2,2-1/2,7 1 1 1 by 3 3/4 3/4 3/4 by 2-1/4

400 600 2,2-1/2,7 1 1 1 by 3 3/4 3/4 3/4 by 2-1/4

600 1000 (see Table 3-

c1Styles 2, 2-1/2, 4, 4-1/2 boxes. Unless other wise specified, when t he ins ide depth of a box is 5 inches or less, end cleat s sh all not be used.

Thickness of th e ends shall be not less than t he combined th ickness of the en d and cleat as s pecified. Each side an d end shall be made fromone piece, except when t he end is appr oxima tely squar e, a two-piece end may be used with each piece of approximat ely equal thickness, a nd

with t he grain of each piece ru nning at r ight angles to the other . Two-piece ends shall be nailed together with a t least t wo clinched nails.2Nominal. The dressed sizes of the wood shall equal or exceed the min imum sizes shown in Table I of STD 20-70. For th e purposes of this

specification, reference to STD 20-70 shall be limited to th e above.3Thickness toleran ce sha ll be plus or minimu m "1/16 inch for par ts 3/8 inch thick and t hicker, unless otherwise specified.4Width t olerance shall be " 1/16 inch unless oth erwise specified.

Table 3-4. Boxes for overseas shipm ent, type 3 (difficult) load; thickness of sides, tops, bott oms, and ends , and t hickness an d width of

cleats.

Weight of content s

Style of box1


Exceeding Not

exceeding

Thickness of

sides, tops,

an d

bottoms2

Thickness

of ends2

Thickness

and width of

cleats2

Thickness of

sides, tops,

and bottoms

Thickness

of ends

Thickness and

width of cleat s4


-- 100 4,4-1/2,5 1/2 1 1 by 3 1/2 1/2 1/2 by 1-3/4

-- 100 2,2-1/2,7 1/2 5/8 5/8 by 3 1/2 1/2 1/2 by 1-3/4

100 250 4,4-1/2,5 5/8 1 1 by 3 1/2 3/4 3/4 by 2-1/4

100 250 2,2-1/2,7 5/8 5/8 1 by 3 1/2 3/4 1/2 by 2-1/4

250 400 4,4-1/2,5 1 1-1/4 1-1/4 by 4 3/4 7/8 7/8 by 2-5/8

250 400 2,2-1/2,7 1 1 1-1/4 by 4 3/4 3/4 3/4 by 2-5/8

400 600 2,2-1/2,7 1 1 1-1/4 by 4 3/4 7/8 7/8 by 2-5/8

600 800 2,2-1/2,7 1 1-1/4 1-1/4 by 4 3/4 7/8 7/8 by 2-5/8

800 1000 2,2-1/2,7 1-1/4 1-1/2 1-1/2 by 5 7/8 1-3/8 1-3/8 by 3-1/4

1Styles 2, 2-1/2, 4, 4-1/2 boxes. Unless other wise specified, when t he inside dept h of a box is 5 inches or less, end cleats shall not be used.

Thickness of th e ends shall be not less than t he combined th ickness of the en d and cleat as s pecified. Each side an d end shall be made from

one piece, except when t he end is appr oxima tely squar e, a two-piece end may be used with each piece of approximat ely equal thickness, a nd

with t he grain of each piece ru nning at r ight angles to the other . Two-piece ends shall be nailed together with a t least t wo clinched nails.2Nominal. The dressed sizes of the wood shall equal or exceed the min imum sizes shown in Table I of STD 20-70. For th e purposes of this

specification, reference to STD 20-70 shall be limited to th e above.3Thickness toleran ce shall be plus or m inimum 1/16 inch for par ts 3/8 inch thick and t hicker, unless other wise specified.4Width t olerance shall be " 1/16 inch unless oth erwise specified.




3-18

Table 3-5. Num ber of Pieces in any Box Part .

Widt h of box par t Maximum number of

pieces single solid or

built-up

Exceeding Not exceeding

Inches Inches

0 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2 -1 /2 .. .. .. .. .. .. .. .. .. .. .. .. .. 1

2 -..1 /2 ........ ....... ...... .. 5 .. ....... ....... ....... ...... ... 2

5 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 7 -1 /2 .. .. .. .. .. .. .. .. .. .. .. .. .. 3

7 -1 /2 ... ....... ....... ...... .. 1 2...... ....... ....... ....... ... 4

12. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. (See note )

Note: The width of pieces in box par ts exceeding 12 inches the a verage width of pieces shall be not less thea n 3 inches.

No single solid or built-up piece shall be less tha n 2-1/2 inches in width across th e space.

Ad d i t i on a l C le a t s a n d B a t t e n s

Additional cleats will be made of the sam e size lumber as t he r egular cleats.

They are placed on the ends of a box when required, according to length of

un supported span (table 3-6). Additional cleats applied to ends r un across

the grain of the end (right angle to grain direction) and midway between the

regular cleats. Batt ens are made of the sam e size lumber as regular cleat s.

Batt ens ar e used on the sides, top, and bottom when t he limit of un supported

span is exceeded (ta ble 3-6). Where ver possible, an d without increa sing the

size of the container, battens should be placed inside the box. When battens

are r equired to be placed on th e outside of a box without sk ids, not less th an

two sets shall be atta ched across the sides, top, and bottom. They shall be

applied so that those on the top and bottom extend over the ends of the side

batt ens. They shall be located not less tha n 2 1/2 inches nor more tha n one-

sixth t he length of th e box with r espect to each box end. However, tha t

distance and the interval between sets of battens shall be not more thanmaximum sp an specified in ta ble 3-6. Exterior batten s shall be applied to

boxes with skids in the same manner as required for interior battens except

that the bottom battens shall be fabricated from one piece of lumber a

minim um of 2 1/2 inches h igh an d 3 1/2 inches wide.

Dia gon als ( f ig 3-12)

Sometimes diagona l reinforcing mem bers ar e added to the interior or exterior

surfaces of the box. Diagona ls used on both th e end an d side panels are th e

same width and thickness as required for cleats and are nailed in the same

man ner. The presence of interm ediate batten s or cleats, required by table 3-

6, determine t he n umber of single diagonals on each pa nel. Single diagonals

in each of two adjacent areas of one panel are arranged to peak at the center

and bear at the upper end of the intermediate batten. Three or morediagonals in adjacent areas of one panel are arranged in a zigzag manner.

When a 24-inch minimum strapping interval is required, the inner surface of

the exterior diagonals must be notched slightly to permit the strapping to

pass un der each diagona l.

S k i d s

Boxes (except style 7) with items packed therein, having a gross weight in

excess of 200 pounds, or containers with length and width dimensions of 48

inches by 24 inches or more and weighing more than 100 pounds, shall be

provided with a minimu m of two skids. The skids shall be fabricated from

one piece of 2 1/2 inches high an d 3 1/2 inches wide. Skids sh all replace




3-19

exterior battens on box bottoms when battens are required in table 3-6.

Skids shall be placed par allel to and extend t he full width of th e box and shall

be positioned n ot closer th an 2 1/2 inches nor more t ha n one sixth the length

of the box from each end of the box. The distan ce between skids, measur ed

between th e inside edges, sha ll not exceed the d istance between batt ens, an d

when ba tten s are n ot required, shall not exceed 48 inches. Additiona l skid(s),

as required, shall be positioned so as to divide the distance between the end

skids into units of equal length. When bolt fastening is provided for t he itembeing packed, additional skids, as needed, shall be located on the box bottom

so as to enable the item to be bolted thr ough the skids. The skids shall be

notched as applicable to provide clearance for either girthwise or lengthwise

stra pping. When 4-way fork ent ry is required, skids shall be a minimu m of 3

1/2 inches high and 3 1/2 inches wide, cut out a min imum of 2 inches, in

depth an d of such width as t o accommodat e forks a nd slings for han dling, and

may be placed length wise flush with th e box sides. The skids shall be

secur ed to the box by nails. The na ils shall be driven from the inside th rough

the bottom into th e skids and be clinched not less than 1/8 inch. Altern ative

to clinching, n ails conforming t o Type II, style 18 of ASTM F 1667-95 ma y be

used of such length as to penetrate a minimum of 3/4 the thickness of the

skids an d shall not protrude thr ough the skid. The nails shall be arran ged in

two rows in a staggered pattern, with space between nails in each row not to

exceed 6 inches. Na ils sha ll not be located less th an 1/2 inch from edges of

the skid nor less than approximately 1 1/2 inches from ends of the skid.

Variation in specified thickness of skids may be plus or minus 1/8 inch and

th e variat ion in specified width of skids ma y be plus or minu s 1/4 inch. When

skids are specified and box requires 2 or more inside battens (table 3-6), the

inside bottom batt ens need not be applied. However, a skid shall be att ached

to the outside of the box bottom placed in alignment with each side bat ten.

Table 3-6. Requiremen ts for Additional Batt ens or Cleats.

Thickness of ends, side, top, or bot t om Maximum

length of

unsupportedspan

Groups I and II woods Groups III and

IV woods

Inches Inches Inches

.............................. 1/4 19

3/8 ........................... 21

............................ 3/8 23

1/2 ........................... 30

.......................... 1/2 34

5/8 ........................... 38

.......................... 5/8 42

......................... 3/4 47

1 ........................... 50

........................... 13/16 54

1-1/4 7/8 64




3-20

Figur e 3-12. Style 2 reinforced box.

NAILING RE QUIREMENTS

SP ACING AND S IZES

Na il spacing an d sizes will conform to ta bles 3-8 an d 3-9.

NAILING OF TOP AND B OTTOM

When specified, the t op and bottom sh ould be na iled to t he box sides.

NAI L S IZES

Sizes of nails are determined from the following information:

• Nail sizes for fastening sides, top, and bottom to ends and cleats aredetermined by the group of wood and thickness of the pieces being

fastened together (table 3-7).

• Nail sizes to secure top and bottom to the sides are determined from

the group of wood being used and the thickness of the side (table 3-8).

• Nails to fasten cleats to the ends will be long enough to penetrate

both the cleat and the end and be clinched at least one-eighth of an

inch. However, when eightpen ny nails or sma ller are u sed, they may

be clinched not more th an thr ee-eighth s inch.

• If correct nail size is not available, or splitting is encountered, one

size smaller is used, and the spacing will be one-fourth of an inch

closer.




3-21

NAI L SPACING

The spa cing of na ils is deter min ed from th e following:

• Nail spacing for fastening sides, top, an bottom to the ends will

depend on the size of nails used, and whether driven into side-grain

or end-grain. If nails are driven into both side- an d end-grain , the

spacing is the same as for end-grain nailing (table 3-9).• Nail spacing for fastening th e top an d bottom to th e sides of th e box is

determ ined from th e thickness of sides. If the thickness of the sides

is less tha n th ree-fourth s of an inch, no nailing is permitted. There is

a minimu m an d ma ximum spa cing (table 3-8).

When attaching cleats and battens, the nails are driven in two parallel rows

spaced alternately as given in table 3-9, so that the end nails are not less

tha n th ree-fourth s of an inch from the end of th e cleat or batten. All nails

shall pass through both the cleat and the end (or batten and side, top and

bottom) and be clinched. Nails are dr iven a pproxima tely three-eighth s of an

inch from the edge when th e cleat or batten is 2 inches or under in width, an d

one-half of an inch when it is over 2 inches in width.

NAILING R ULES

It is imperative that poor nailing practices be avoided and correct nailing

procedur es be followed. Both ar e shown in figur es 3-13 an d 3-14, an d

stressed in t he following r ules:

• Each single solid piece or built-up piece in the sides, top, or bottom

will have at least two nails or other acceptable fasten er at each end.

• Each single piece or built-up piece is fastened to each vertical cleat or

batt en with n ot less tha n two nails or other a cceptable fasten er.

• Wher ever possible, side-grain nailing should be accomplishe d. In

nailing to both the end and the cleats, at least half of the nails are

driven into th e cleat.• Where a cleat is attached to an end, at least one end nail will be

adjacent to the inside edge of the cleat.

• Na ils are clinched a cross the gr ain of th e wood, if possible.

• Nails must be driven so tha t n either th e head n or the point will project

above the su rface of th e wood.

• Occasionally, overdriven nails are permitted. Nails overdriven more

tha n one-eight h th e thickness of the piece are not perm itted.

• Cement-coated or chemically-etched nails have a holding power

considerably greater than that of uncoated and consequently 25

percent more na ils of the sa me size are needed when smooth na ils are

used in place of cement -coated or chem ically-etched na ils. The

comparative holding power of nails is illustrated in figure 3-15.

Bright, un coated na ils mu st be clinched.




3-22

Table 3-7. Size of cement-coat ed or chemically-etched cooler, sinker , and st anda rd box nails for boxes.

Species of wood Thickness of ends or cleats to which sides, tops and bottoms are nailed (inch)

Exceeding ........

..

7/16 1/2 9/16 5/8 11/16 13/16 7/8 1 1-1/8 1-1/4

Not exceeding 7/16 1/2 9/16 5/8 11/16 13/16 7/8 1 1-1/8 1-1/4 ......

G rou p I ............ S ize of

nail (penny)

4 5 5 6 7 8 8 9 9 10 12

Group II........... 4 4 5 5 6 7 7 8 9 9 12

Group III ............ 3 4 4 5 5 6 7 7 8 9 10

Group IV......... 3 3 4 4 4 5 6 7 8 8 9

Table 3-8. Size of nails a nd spacing for nailing tops an d bottoms t o sides of boxes.

Thickness of side (inches) Gr oup I wood G roup II wood Gr oups III and IV woods Spa cing

Minimum Maximum

U n de r 3 /4 ........... ......... . N o n a il in g p er m it t ed

3/4 thru 7/8 incl............. 7d 6d 5d 6 8

15/16 thru 1-1/16 incl..... 8d 7d 6d 6 8

Over 1-1/16................... 10d 9d 8d 8 10

Table 3-9. Spacing of cement -coated or chemically-etched nails for boxes.

Size of Nails Spacing when dr iven

into side grain

Spacing when driven

into end grain 1

Inches Inches

Sixpenny or smaller 2 1-3/4

Sevenpenny........... 2-1/4 2

Eightpenny............. 2-1/2 2-1/4

Ninepenny.............. 2-3/4 2-1/2

Tenpenny............... 3 2-3/4

Twelvepenny.......... 3-1/2 3

Sixteenpenny......... 4 311/2

Twentypenny.......... 4-1/2 4

1When nails a re alt erna tely driven into end-grain of end and side-grain of cleat

(such as n ailing sides t o ends in St yles 2, 2-1/2, 3, 4, 4-1/2, 5 and 7) use spa cing

based on driving nails into end-grain.




3-23

Figur e 3-13. Na iling.

SETTING UP OF STYLE 1 AN D 6 BOXES

The set ting u p of th ese styles is accomplished in t he following order :

• Select n ails and glue.

ο Size of coated and etched nails and proper spacing is determined

from ta bles 3-7, 3-8, and 3-9.

ο Glue for securing sides to ends of Style 6, lock-corner box, is any

commercially available wat er-resistan t glue.

ο Fasten the sides to the ends by straight-line nailing, using cement-

coat ed or chem ically-etched na ils.

ο

Apply glue to both surfaces of the sides and ends of the lock-corn ers of Style 6 boxes.

ο Nail the top and bottom.

ο Use na ils an d proper spacing determined a bove.

ο Secur e th e bottom of the box by nailing into the ends.

ο After the load is inserted, secure the top of the box in the same

mann er as the bottom.




3-24

Figure 3-14. Pr oper an d improper nailing.

SETTING UP OF STYLE 2 AN D 2 1/2 BOXES


• Select n ails and proper spa cing.

ο Select proper size and spacing of coated or etched, and bright,

uncoated nails from tables 3-7 and 3-8.

ο Fasten t he cleats to the ends.

ο Nail cleats to end, using a staggered na iling patter n.

ο Nails for nailing cleats to ends may be bright, uncoated, but must

be clinched .

ο Position t he vertical cleats on the en d at right a ngles to the grain of

the end.

ο Fasten t he sides to the ends.

ο Lap th e sides over th e ends an d cleats.

ο Nail the sides to the ends a nd cleats with coated or etched na ils in a

staggered pattern .

ο Nail the top and bottom.

ο Lap th e top and bottom over the ends a nd cleats.

ο Nail the top and bottom to the ends and cleats with coated or

etched na ils in a staggered patt ern.




3-25

Figur e 3-15. Na il holding power.




3-26

Set t in g u p of s ty le 4 , 4 1 /2 , 5 , an d sh a l low boxe s


• Select na ils and pr oper spacing. Select th e proper size and spacing of

coated or etched, an d bright, u ncoated na ils from ta bles 3-7, 3-8, and 3-

9.

• Fasten the cleats to the ends.

• Nail the cleats to the end using a staggering nailing patt ern.

• Nails for nailing the cleats to the ends may be bright, uncoated, but

must be clinched.

• Fasten the sides to the ends.

• Lap th e sides over th e ends a nd cleats on Style 4 and 5 boxes.

• Fast en th e sides to the ends a nd cleats in a sta ggering nailing pattern .

• Lap t he sides of Style 4 1/2 and sh allow box over th e end s.

• Drive the nails in a straight line for Style 4 1/2 box and in a staggered

pat tern for shallow boxes.

• Nail the top and bottom.

ο Nail the bottom of th e box to the en ds an d sides.

ο On Style 4 and 5, boxes nail the top and bottom to the end with

stra ightline na iling.ο On Style 4 1/2 and shallow boxes, nail the top and bottom to the

ends with a staggered na iling pattern.

S t r a p p i n g R e q u i r e m e n t s

Stra pping used on nailed wood boxes may be either round or flat. Proper size

of strapping is determined by the net weight of contents and the number of

stra ps used (tables 3-10 and 3-11). All straps ar e applied perpendicular t o the

edges of the box over which they pass a nd a re dr awn t ight so as to sink int o the

wood at th e edges. Stra ps shall be applied just prior to shipment wh ere

pra cticable. Stra pping requiremen ts a re foun d in th e Appendix to Specification

PPP-B-621.

C LASS 1 (D OMESTIC) B OXESUnless otherwise specified, Style 1 and 6 boxes, regardless of weight, and Style

2, 2 1/2, 4 4 1/2, 5, and 7 boxes, with weight of contents exceeding 100 pounds,

sha ll be stra pped. When sp ecified, Style 2, 2 1/2, 4 4 1/2, and 5 boxes, with

weight of content s less tha n 100 pounds, sha ll be stra pped.

C LASS 2 (O VERSEA) B OXES

All boxes used for a sh ipmen t int end ed for oversea s sha ll be str app ed (fig 3-16).

P l a c e m e n t o f St r a p s

On m ost boxes, the first stra ps ar e positioned girth wise about one-sixth of the

length of the box from each end, not to exceed 9 inches from the ends.

On Styles 1 and 6, the first strap is lengthwise, followed by two girthwisestraps.

When strapping is required on Style 7 boxes, one strap is applied parallel to,

and imm ediately adjoining the inner edge of each skid. Three or more stra ps,

equally spaced, are r equired when spacing between stra ps exceeds 24 inches.




3-27

Table 3-10. Minimum gage of round wir e for var ious weights of boxes.

Net weight of contents Gage of wire when differ rent number of wires are used

Two bands Three or more bands

Exceeding Not exceeding Class B Class A Class B Class A

Pounds Pounds Inch Inch Inch Inch

0........................ 70..................... 0.0720 (15 ga ge) 0.0625 (16 ga ge) 0.0720 (15 ga ge) 0.0625 (16 ga ge)

70...................... 125.................... 0.0800 (14 ga ge) 0.0720 (15 ga ge) 0.0800 (14 ga ge) 0.0720 (15 ga ge)

125.................... 175.................... 0.0915 (13 ga ge) 0.0800 (14 ga ge) 0.0915 (13 ga ge) 0.0800 (14 ga ge)

175.................... 250.................... 0.0915 (13 ga ge) 0.0915 (13 ga ge) 0.0915 (13 ga ge) 0.0915 (13 ga ge)

250.................... 400.................... 0.1055 (12 ga ge) 0.0990 (12-1/2 ga ge) 0.0915 (13 ga ge) 0.0915 (13 ga ge)

4 00 ... ....... ....... ... 1 ,0 00 .. ....... ....... ..... .... ....... ....... ....... ... . ....... ....... ....... ....... .. 0 .1 05 5 (1 2 ga ge ) 0 .0 99 0 (1 2-1 /2 g a ge )

Table 3-11. Minimum sizes of flat met al bands for various weigths of boxes.

N et w ei gh t of con t en t s D im en s ion s of fl at m et a l b an d s w he n d iffe re nt

numbers of bands are used

Exceeding Not exceeding Two bands Three or more bands

................. 70............. 3/8 by 0.015...... 3/8 by 0.015

70............. 125............ 3/8 by 0.020...... 3/8 by 0.020

125........... 175........... 1/2 by 0.020...... 1/2 by 0.020

175........... 250............ 5/8 by 0.020..... 5/8 by 0.020

250........... 400............ 3/4 by 0.020..... 3/4 by 0.020

400........... 1,000......... ...................... 3/4 by 0.023

Additiona l straps a re placed girth wise so that the dista nce between st rap s does

not exceed 24 inches.

Small boxes less than 12 inches long and having less than 35 pounds of

contents r equire only one girthwise strap. The single girth wise stra p may be

16 gage roun d wire, or 3/8 X 0.010-inch flat st ra p.

When the outside length of unreinforced style 2, 2 1/2, 4, 4 1/2, 5 and shallow

boxes exceeds 36 inches, thr ee or more st rap s will be applied girthwise so t hat

the dista nce between str aps is not more than 24 inches.

W o r k m a n s h i p

Throughout the fabrication, setting up, nailing, and strapping of nailed wood

boxes, good work ma nsh ip should be pra cticed at all times. Figur e 3-17 shows

some of th e defects wh ich m ust be avoided.




3-28

Figur e 3-16. Str app ing of na iled wood boxes.




3-29

Figur e 3-17. Defects of nailed wood boxes.




3-30

P r e s e r v a t i o n

When specified, each PPP-B-621 box or all of the finished wood parts shall be

preserved by immersing for a minimum of one minute in one of the following

wood preservat ive solutions: 2 percent copper Mapht hen ate, 3 percent zinc

nap hth enat e, or 1.8 percent copper-8-quinolinolate. These three chemicals

exhibit characteristics which are acceptable for DOD-wide use provided

ha ndling instr uctions prescribed by the ma nu factu rer ar e followed. After th e

dip treatment, the boxes or wood parts must be air dried (or dried for anappr opriate time in a k iln or oven) for a per iod of 24 hours minimum in a well-

ventilated area allowing full air circulation around all surfaces of the

individua l wood box or wood part. The boxes or pa rts m ust be dr ied prior to

shipment . Dryness can be determ ined by the absence of discoloration of the red

oil soluble dye when test ed as sp ecified in P PP -B-621.

CLEATED-P ANEL BOXES (GENER AL)

DE S C R I P T I O N

Cleated-panel boxes are made by attaching wood cleats to sheets of plywood,

fiberboard, or paper-overlaid veneer to form panels that are later fastened

together a t the cleats to form a container. When plywood is used as panelmaterial, they are called wood-cleated plywood boxes, specification PPP-B-601;

when fiberboard is used, they are called wood-cleated fiberboard boxes,

specification PPP-B-576; and when paper-overlaid veneer is used, they are

called wood-cleated , pap er-overla id veneer boxes. In each type of box, th e

cleats a ct to reinforce the edges and to aid in n ailing.

C HARACTERISTICS

The chief char acter istics of cleat ed-pan el boxes ar e: Lightweigh t, high

resistance to diagonal distortion, resistance to corner damage, and ability to

withsta nd severe tumbling an d dropping. They are easy to mar k and han dle,

almost dustpr oof, and lend th emselves to easy fabrication. Pan els may be

bought in large quantities in the knocked-down form, which can be easily

stored in a m inimu m of spa ce. These boxes afford t hr ee choices of cleat ed pan elboxes for use in th e shipping of militar y supplies and equ ipmen t. Selection of

the panel material for the box is based upon the destination of the shipment,

the minimum protection required, the weight of the item, and the container

limitations.

I n t e n d e d U s e s a n d L i m i t a t i on s

The styles of boxes permitted for domestic and oversea shipments, with

limitations for cleated plywood, cleated fiberboard, and cleated paper overlaid

veneer boxes are cited in table 3-12.

Over sea Typ e Boxes ( see figur e 3-18)

Styles A and B are the only ones permitted, for cleated fiberboard and veneer.

Cleated plywood boxes perm it Styles A, B, I, and J . Plywood and pap er-overlaid boxes will take a ll th ree types of load s. Cleated fiberboard boxes will

ta ke Type 1 an d 2 loads only. Style A lends itself to ease of asse mbly and

opening. Style B has greater st rength , but is more difficult to open. The

designs of these boxes and their load limit for oversea shipments are given in

the respective container specifications.




3-31

Figur e 3-18. Oversea st yles of cleat ed pan el boxes.

Dom es t i c Type Boxes (see f igur e 3-19)

Domestic boxes are intended f or normal use when the additional strength of

the oversea type is not required. The selection of th e style depends largely on

the n atu re an d weight of the item, an d how it is to be supported. Styles B, D,

E, an d G ha ve 3-way corn ers an d ar e satisfactory if the boxes are n ot to opened

for insp ection a nd r eclosed. If the boxes ar e to be opened an d reclosed, Style A

and K ar e preferred. The full-cleated Styles A an d B ar e the strongest and

most suitable for h eavy items, if the weight can be applied over t he en tire a rea

of an y face. Styles A an d B requir e only one size of na ils for assem bling the

box, whereas, two sizes of nails are required for Styles C and K, inclusive.

Paper-overlaid veneer boxes are only available in Styles A and B for domestic

shipment . All thr ee types of loads ar e permitted.




3-32

Figur e 3-19. Styles of cleat ed pan el boxes.




3-33

Table 3-12. Comparison of cleated pa nel boxes.

Items of compar ison Cleat ed plywood (PPP-B-601) Paper over laid veneer

(PPP-B-576)

S tyle s.................................. A, B, I a n d J ........................ A a n d B .

Cla ss of u se....................... dom est ic a nd over sea s....... 1 a nd 2

St yles, over sea .................. A, B, I an d J ........................ A a nd B

St yles, dom es tic................ A, B, I an d J ........................ A a nd B

Weight limit vs. styles

Over sea ............................ A, B, I a nd J 1,000#............. A a nd B - 350#

Dom es tic.......................... A, B, I a nd J 1,000#............. A a nd B - 400#

Typ es of loa ds vs . we igh t .. 1 , 2 an d 3............................. T yp e 1 - 2 D om es tic 400 #

Type 3 - Domestic 300#

Type 1 - 2 Overseas 350#

Type 3 - Overseas 250#

Unsupported span for

intermediate cleats, maximum

Type 1 and 2 loads - 24"......

Type 3 loa d - 20"..................

Type 3 load, Class 2 use - 20"

All other - 24"

Size limitOver se a............................ N o size l im it ......................... N o size l im it

Dom es tic.......................... N o s ize lim it ......................... N o s ize lim it

Strapping

St yles A an d B..................

2 lengthwise straps, and strap

over a ll intermediate cleats,

except cleats located on ends of

plywood container s

All class 2 boxes and Class 1 when

over 150#

S t yl es C t h r u K..... ....... ...... C on su lt Ap pe nd ix of S pe ci fi ca t ion

S taples .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 4" max imum f rom corners, approx imate ly 6" apar t the rea fte r (except

over ban ds on bottom of box for plywood)

Table 3-13. Plywood PS-1 and PS-51, comm ercial stan dar ds.

Box type PS-51 PS-1

Domest ic. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. Type I I I, grade 3 -4 veneers. .. .. .. .. .. .. .. .. .. .. .. C -D

Overseas. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . Type I , g rade 3 -4 veneers .. .. .. .. .. .. .. .. .. .. .. .. C -D, with ex ter ior

1Plywood is furnished un san ded. If smooth finish or snaded panels ar erquir ed, appropriated san ded grades should be specified in the contract

or order.2End grain butt joints shall be prohibitied for grade 4 veneers.




3-34

CLE ATED P LYWOOD BOXES (PP P -B-601)

C ONSTRUCTION OF P ANELS

Plywood will conform to th e minimu m commer cial sta nda rd gr ades in table 3-

13. Plywood for domest ic boxes will conform to H PMA-HP 1983, Type III,

Gra de 3-4, and PS -1, sta nd ar d inter ior. Plywood for oversea boxes will conform

to HPMA-AP 1983, Type I, Grade 3-4, and P S-1, stan dar d inter ior with exterior

glue (see tables 3-14, 3-15). If it is kn own th at th e boxes will not be exposed to

the weather during storage and handling to its final oversea destination,

plywood as specified for domest ic type boxes should be specified. Cleated -

plywood boxes are classified as Grade A, with preservative treatment, and

Grade B, without preservative treatm ent. Plywood an d cleats for Grade A

boxes shall be treated with water-repellant preservative conforming to the

following: 2% copper Map ht hen at e, 3% zinc na pht hen at e, and 1.8% copper -8-

quinolate. Treated boxes sha ll be dried before shipment . Shipment s of

subsistence and clothing shall not be made in boxes fabricated from toxic

trea ted plywood. If smooth finish for sanded pan els are r equired, appropriate

sand ed grades should be specified. The minimu m t hickness of the plywood and

size of cleat s should be as shown in t ables 3-14 or 3-15, as ap plicable. The

plywood is at tached t o the cleats in t he following m ann er:

Ar r a n g e t h e C le a t s

Each panel for styles A and B will have two through cleats and filler cleats.

Position the through cleats opposite each other at the edges of the panel

mat erial; th en position the filler cleats between th e thr ough cleats at th e edges.

Style A an d B boxes may ha ve the top pa nel modified. When sp ecified, style A

shall ha ve edge cleats a nd filler edge cleats placed on t he u nder side of the top

pan el (fig 3-20). Style B boxes are m odified by providing th rough edge cleat s

only on the un derside of the pan el. These un derside cleats sha ll be of the same

width an d thickness as the outer cleats.

Table 3-14. Domestic type, requirem ents for cleats a nd plywood (PPP-B-601).

St yle of boxWeight of contents Minimum t hickness of plywood Size of clea ts1

Exceeding Not exceeding PS-1 (see t able

3-13)2

HPMA-HP 1983

(see table 3-13)3Thickness Widt h

All Wood grou ps

(incl)

All Wood group s

(Incl)

Pounds Pounds Inch Inch Inch Inches

A, B, I and J 0 75 5/164 6 1/8 3/4 1-3/8

A, B, I and J 75 150 5/164 6 1/8 3/4 1-3/4

A, B, I and J 150 300 5/164 6 3/164 3/4 1-3/4

A, B, I and J 300 500 5/16 6 3/16 3/4 1-3/4

A, B, I and J 500 800 5/16 1/4 3/4 2-1/4

A, B, I and J 800 1000 3/8 5/16 3/4 2-5/8

1At no place shall the actual t hickness be less than the required th ickness, minus 1/16 inch, nor t he actual width be less than the r equired

width, minus 1/4 inch.2Alterna tively low density wood plywood conforming t o HPMA-HP 1983 (ta ble 3-13) ma y be used.3Low density wood plywood conforming t o HPMA-HP 1983 (ta ble 3-13) shall n ot be us ed.43/30 minimum inch th ick plywood conforming to t ype III, gra de 4 of HPMA-HP 1983 ma y be used in place of the 5/16 inch (3/20 th ick plywood

is not st andard thickness in HPMA-HP 1983).5Except that commercial tolerance shall apply.6At th e option of the supplier, 1/14-inch san ded plywood may be furnish ed.




3-35

Table 3-15. Overseas t ype, requirement s for cleats an d plywood (PPP -B-601).

Weigh t of con ten ts Min im um th ickn ess of plywood6 Sizes of edge cleats for

all groups1

Exceeding Not

exceeding

Types 1 and 2 loads Type 3 load Thickness Widt h

PS-1 (see table

3-13)2

HPMA-HP 1983

(see table 3-13)3

PS-1 (see table

3-13)2

HPMA-HP 1983

(see table 3-13)3

Style Style St yle St yle

A&B I and J 4 A&B I and J 4 A&B I and J 4 7 A&B I and J 47

Pounds Pounds Inch Inch Inch Inch Inch Inch Inch Inch Inch Inch

0

100

200

300

400

500

600

800

100

200

300

400

500

600

800

1000

5/168

5/168

5/168

5/168

5/168

5/16

3/8

3/8

3/8

3/8

1/2

1/2

1/2

1/2

5/8

5/8

3/165

3/165

3/16

3/16

3/16

1/4

5/16

5/16

5/16

5/16

3/8

3/8

3/8

3/8

1/2

1/2

5/168

5/168

5/16

5/16

5/16

5/16

3/8

1/2

3/8

3/8

1/2

1/2

5/8

5/8

5/8

5/8

3/165

3/16

1/4

1/4

1/4

1/4

5/16

3/8

5/16

5/16

3/8

3/8

1/2

1/2

5/8

5/8

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

1-3/4

1-3/4

1-3/4

1-3/4

2-1/4

2-5/8

3-1/4

3-1/4

1At no place shall the actual thickness be less than the r equired thickness, minimum 1/16 inch, not the actua l width be less than t he required

width, min us 1/4 inch.

2Alterna tively low density wood plywood conforming t o HPMA-HP 1983 (ta ble 3-13) ma y be used.3Low density wood plywood conforming t o HPMA-HP 1983 (ta ble 3-13) shall n ot be us ed.

4Top and bottom pa nels of I and J boxes only, all other panels a s specified for st yles A and B.5Minimum 3/20 inch th ick plywood conform ing to type I, grade 4 of HPMA-HP 1983 ma y be used in place of the 3/16 inch th ick plywood. (3/20

inch thick plywood is not a sta ndar d thickness in H PMA-HP 1983).6Except that commercial tolerance shall apply.7The maxim um weight of content s for Air Force shipment s for st yle I and shall be 150 lbs.8At th e option of the supplier, 1/4 inch sanded plywood may be furnished.

Figur e 3-20. Top pane l modificat ion of unn ailed closure, P PP -B-601, style A box.




3-36

Unless otherwise specified filler edge cleats shall be either th e sam e length as

the d istance between th e th rough edge cleats or a pproximat ely one-eighth inch

shorter.

Filler edge cleats on top and bottom panels, except on top only when the box is

provided with skids, shall be either the same length as the distance between

the through edge cleats or approximately one-fourth inch shorter for oversea

type boxes.

When the filler cleats are the same length as the distance between through

edge cleats, each end shall be either cut at an angle or notched to provide a

drainage area between the filler cleat and the plywood of approximately one-

fourth inch by one-four th inch. Draina ge areas are not applicable on th e

underside cleats of the top panels of the unnailed closure Style A box.

Each cleat shall be a single u njointed piece.

Fast en t he pa nel mat erial to the cleats (fig 3-21).

Nails, staples, wire stitches, or other fasteners positioned lengthwise of a cleat

are staggered in two parallel rows, approximately three-eighths inch from the

edge of th e cleat .

The distance between the nearest edge of a fastener and the edge of a cleat

shall not be less tha n th ree-eighth s of an inch an d not closer th an thr ee-four ths

of an inch nor more th an 1 inch from th e end of the cleat.

Space the nails not more tha n 6 inches apa rt length wise in each row. Usua lly,

nail or sta ple through t he plywood and th en cleat a nd clinch. Reversal of this

sequence is permitt ed only for na ils.

Cons t r uc t i on o f P l ywood J o i n t s

In the construction of large cleated plywood boxes, it frequently becomesnecessar y to join sheets of pan el ma ter ial. Bottom pan els of boxes not

exceeding 72 inches in length or 48 inches in width, an d top an d bottom pan els

of Style I boxes sha ll consist of a single piece of plywood. All oth er p an els sha ll

consist of one or two pieces of plywood joined by either a lap or butt joint (see

fig 3-22) as specified below. Ea ch piece of plywood in two-piece pa ne ls sha ll be

not less tha n 24 inches in length or width. Plywood joint s in adjacent pa nels

should n ot be closer t ha n 12 inches of being in line.

Lap J o i n t

Overlap two pieces of pan el ma terial at least 3 inches. Fast en the sheet

together with m etal stitches thr ough the overlap and clinch. Use not less than

two par allel rows of stitches. Space stitches not less tha n 2 inches apar t. The

average spacing of stitches in each row must n ot exceed 4 inches. Themaximum thickness of plywood to be used for this type of joint shall be 3/16

inch.

Bu t t Jo i n t

But t two pieces of plywood at t he m idwidth of a joint cleat . Fa sten each piece

of plywood to th e joint cleat. The t hickness of a joint cleat will be the sa me a s

an e dge cleat . The width of a joint cleat for a domestic box will be no less th an

2 1/4 inches. If the edge cleat is m ore tha n 2 1/4 inches wide, the joint cleat will

be of th e same widt h. For oversea type boxes, th e joint cleat will be not less




3-37

than 1 1/3 times the required width of the edge cleats or never less than 2 1/4

inches.

De t er m i ne t he R equ i r emen t s

Additional wood cleats, of the same width and tickness as the edge cleat, are

applied to an unframed area which exceeds 24 inches in any dimension or 20

inches for oversea type boxes with Type 3 loads. Aditional cleats are applied to

any face of a box having a load concentration near the center of the unframedarea.

Fas t en t he C l ea t s

Apply cleats perpendicular to the greater of the two dimensions between edge

cleats. Space and drive fasten ings in th e same man ner a s for edge cleats.

ASSEMBLY OF BOXES

Style A (Oversea )

Assembly Of The Pa nels

Arrange the panels so that one through cleat and one filler cleat forms each

edge of th e box. Arra nge th e cleats t o form a st an da rd box corner (fig 3-18).

Arran ge the top and bottom panels to overlap the sides and en ds.

Na i l i ng t h e Pan e l s Toge t her

Nail all panels to each other by single line na iling. Use either mechanically

deform ed, cement coat ed or chemically-etched na ils. Spa ce th e na ils in

accordance with the type of load and the thickness of cleats (tables 3-16 and

17).

Figur e 3-21. Spa cing of fasten ers.




3-38

Figur e 3-22. Acceptable plywood joints .

Table 3-16. Domestic type, sizes and spacing of nails for fastening

together adjacent cleated panels.

Cleats

Thickness

Maximum spacing of nails

all wood groups

Size of nails for wood groups 1

Types 1

and 2

loads

Type 3

load

I II III IV

Inch 3/4 Inches 5 Inches 4 Penny 7 Penny 7 Penny 7 Penny 6

1If the nail protrudes t hrough the last edge clear or splits cleat, t hen th e next

smaller size penny nail shall be used.

Table 3-17. Oversea type, sizes and spacing of nails for fast ening together adja cent cleated panels.

C lea ts, th ickness (Inch) Maximum spacing of na il s,

all wood groups

Size of nails for wood groups 1

Types 1 and 2

loads

Type 3 load I II III IV

3/4................................. Inches 5 Inches 4 Penny 9 Penny 8 Penny 7 Penny 6

1If the nail protrudes t hrough the last edge cleat or if it splits the cleat, then t he next sma ller size penny nail shall be used.




3-39

Table 3-18. Diamet er of round wire stra pping.

Diameter of wire when different numbers of wire are used

Weight of content s 2 wires 3 or more wires

100,000 pounds per

square inch tensile

strength

140,000 pounds per

square inch tensile

strength

100,000 pounds per

square inch tensile

strength

100,000 pounds per

square inch tensile

strength

Pounds Inch Inch Inch Inch

Up t o 70, incl...........

71 t o 125, incl..........

126 t o 175, incl.......

176 t o 250, incl.......

251 t o 400, incl.......

401 to 1,000, in cl....

0.0720 (15 gage)

0.0800 (14 gage)

0.0915 (13 gage)

0.0915 (13 gage)

.............................

..............................

0.0720 (15 gage)

0.0720 (15 gage)

0.0800 (15 gage)

0.0915 (13 gage)

...............................

................................

0.0720 (15 gage)

0.0800 (14 gage)

0.0915 (13 gage)

0.0915 (13 gage)

0.0915 (13 gage)

0.1055 (12 gage)

0.0720 (15 gage)

0.0720 (15 gage)

0.0800 (14 gage)

0.0915 (13 gage)

0.0915 (13 gage)

0.0990 (12-1/2 gage)

Table 3-19. Size of flat m etal ban ds

Weight of content s

not exceeding

Dimension of flat metal bands when different numbers of

bands are used

2 bands 3 or more bands

Pounds Inch Inch

Up t o 70, incl................. 3/8 by 0.020 3/8 t o 0.020

71 to 125, incl................ 3/8 by .020 3/8 by .202

126 t o 175, incl............. 1/2 by .020 1/2 by .020

176 t o 250, incl............. 5/8 by .020 5/8 by .020

251 t o 400, incl............. 3/4 by .020

401 t o 1000, incl........... 3/4 by .023

Table 3-20. Size of type III, twist-tied flat meta l strap ping

Weight of contents not

exceeding

Dimensions when different numbers of bands

are used

2 st raps 3 or more st raps

Pounds Inch Inch

70 0.140 by 0.031 0.138 by 0.025

St y l e B ( ove r s ea )

Assembly o f the Pa n els

Arrange the panels so that one through cleat and one filler cleat forms each

edge of th e box. Arra nge th e cleats t o form a 3-way int erlocking corn er (see fig

3-18). Arran ge the top and bottom to overlap the sides; then ar ra nge the ends

to overlap the top and bottom and, finally, arrange the sides to overlap the

ends.

Na i l i ng t h e Pan e l s Toge t her

Nail each through cleat to two other through cleats at the corner with nails

driven at right an gles to each other . Nail the panels to each oth er by single

line nailing. Use either m echan ically deformed, cemen t-coat ed, or chemically-

etched nails. Space the nails in accordance with t he type of load an d the

th ickn ess of th e cleat s (table 3-16 an d 3-17).




3-40

Styles A, B, I an d J (Domes t ic )

Four styles are available for domestic use; Styles A, B, I an d J , depending on

the cleat ar ra ngement . A stud y of figure 3-19 shows the cleat a rra ngement for

each style. For Styles I and J the plywood along each un cleated edge is

fastened to the cleat on the adjacent panel by nails passing through the

plywood and int o th e cleat. Nails shall not be less tha n 1 inch longer t han th e

thickness of the plywood through which they pass for domestic type and 1 3/8

inches for oversea t ypes and th eir spacing shall not exceed 3 inches.

App l i ca t i on o f Sk i d s

Unless otherwise specified, boxes with items packed therein, having a gross

weight in excess of 200 pounds or length and width dimensions of 48 inches by

24 inches or more, and gross weight of 100 pounds or over, shall be provided

with a m inimum or two skids. The skids shall be minimum of 2 1/2 inches high

and 3 1/2 inches wide. When 4-way fork ent ry is required, skids sha ll be

nominal 4-by-4-inch, placed lengthwise not less than 1 1/2 inches nor more

tha n 2 1/2 inches from th e container sides and cut out a minimum of 2 inches in

depth a nd of such width a s to accommodat e forks and slings for han dling. Each

skid sha ll be notched sufficiently to provide clear an ce for str app ing. The skids

shall be placed par allel to, and extend t he full width of th e box (th e shorter of

the two horizontal dimensions), and sha ll be set n ot less than 2 1/2 inches nor

more than 1/6 th e box length form each end. The distance between skids,

measu red between th e inside edges, shall not exceed 48 inches. Filler cleats of

the same thickness as the end cleats of the bottom panel and not less than the

width of the sk ids shall be provided between each skid an d th e bottom pa nel of

th e shipping conta iner . Additiona l skid(s), as requ ired, shall be positioned so

as to divide th e area between th e end skids int o un its of equal lengths. When

boltholes are provided in the item, additional skids if needed shall be located so

as to enable the item to be bolted to the skids. The skids shall be secur ed to the

box by na ils. The na ils shall be driven th rough th e bottom pan el, th e filler

cleats, and the skids, and shall penetrate a minimum of three-fourths the skid,

thickness. The na ils shall be pallet na ils ha ving mechan ically deformed sha nks

conforming to ASTM F 1667-95. These nails shall not protrude t hrough t hebottom sur face of the skid. The na ils shall be ar ran ged in two rows in a

staggered pattern, with spacing between nails in each row to be not more than

6 inches. Ea ch row of na ils sha ll be appr oxima tely one-ha lf inch in from th e

edge of the skid and the nailing pattern shall begin and end approximately 1

1/2 inches in from the end of each skid and shall not be nailed through the

strap notch.

Closure

The top panel shall be positioned a nd n ailed. The size and spacing of nails

shall be shown in tables 3-16 and 3-17. Drive na ils stra ight to prevent th em

from protru ding.

S t r a p p i n g R e q u i r em e n t sStrapping requirements are found in the appendix to PPP-B-601. The sizes of

round wire an d flat m etal str aps ar e found in ta ble 3-18, 3-19 and 3-20. Styles

A or B boxes that have modified tops will be closed with flat steel strapping.

Other m eans a re prohibited.

St y l e s A, B, I and J ( Ove r s ea )

Str ap Styles A, B, I an d J , unless other wise specified (see figure 3-23). On

Styles A an d B, apply two lengthwise stra ps on th e edge cleats over t he en ds,

top, an d bottom. On Styles I and J , apply two lengthwise stra ps on th e edge

cleats over the ends and sides. Place a girthwise strap over interm ediate




3-41

cleats, when r equired, on t he sides, top an d bottom (fig 3-24). Draw st rap ping

tightly so as to sink into the edges of th e cleats. Fa sten st rap ping to the cleats

with staples spaced approximately 6 inches apart, and within 4 inches from

the edge of the box over which the strap passes (except over bands on the

bottom of th e box an d bands app lied over filler cleat s on th e top). Sta ples

shall be applied just prior to shipment where pr acticable. Str apping used for

un na iled closure boxes sha ll not be stapled. Altern ately, each length wise and

girthwise strap may be replaced by four corner straps each 8 inches long andsecured to the box with three staples on each leg pneumatically driven

thr ough the stra p into the cleat. However, corner stra ps shall not be used on

un na iled closur e boxes. Exercise car e in str apping domestic styles so tha t t he

straps do not pass over voids between cleats and thus become susceptible to

snagging.

Figur e 3-23. Str app ing of cleat ed pan el boxes.




3-42

Styles A, B, I an d J (Domes t ic )

Stra p domestic styles only where specified. Stra p in accordance to th e

appendix to PPP-B-601.

Dimens ions

Dimensions shall be given in the sequence of length, width and depth of the

inside measurem ents. The first t wo dimensions will be the open face of the

box. A toleran ce of plus or minu s 1/8 inch is perm itted in t he dimen sions.

BOXES, WOOD-CLE ATED P ANELBOARDWood-cleated panelboard boxes are intended for use as containers for domestic

and overseas equ ipment of general m ater ials and supplies, not exceeding 500

pounds for domestic or 400 pounds for overseas shipments.

Wood-cleated, water-overlaid veneer boxes take all three types of loads to a

maximum weight of 500 pounds for domestic use (class 1 boxes), and 400

pound s for oversea u sed (Class 2 boxes), in accordan ce with P PP -B-576. Styles

A and B only are aut horized for both domestic an d oversea sh ipments. Tables

3-21 and 3-22 contain the requirements for the paper-overlaid veneer

panelboard and the cleats for class 1 and 2 boxes, respectively, according tothe weight of conten ts.

Skids are att ached to th e bottom of boxes having a gross weight of more tha n

200 pounds, or when the length and width dimensions are 48 inches by 24

inches or over an d th e gross weight is 100 pounds or over. The skids sha ll be a

minimum of 2 1/2 inches high and 3 1/2 inches wide and m ay be fabricated

from more tha n one piece of lumber to mak e up th e required height. The skids

shall be set not less than 2 1/2 inches not more tha n 4 inches in from each end.

Filler cleats of the same thickness as the edge cleats and the same width as

the sk ids and t he bottom panel of the box.

WOOD-CLEATED , SKIDDE D, LOAD-BEARIN G BASE BOXES

(ASTM D6256)These boxes may be used for t he sh ipment of items which can be secured t o a

load-bearing base. The sides, tops, and ends a re of cleated pa nel constr uction.

Panels may be plywood, fiberboard, or paper-overlaid veneer and comply with

the applicable requirements of PPP-B-601 and PPP-B-576, respectively.

Styles A, B, and C are used for Type I, domestic, and Type II, oversea

shipment s. The bases are fabricated a s Class 1, plywood base, and Class 2,

lumber base (see fig 3-25).

I NTENDED USE

Boxes covered by ASTM D6256 are intended to be used for items which can be

att ached to a load-bearing base. It is intended th at t he entire load be carr ied

on the base. The super-stru cture (tops, ends, and sides) provides only forsuperimposed loads and protection against t he elements. It is not int ended for

the box to be lifted or moved other tha n by the base. The super-stru cture ma y

be removed when it is not required.




3-43

Figur e 3-24. Spa cing of inter media te cleats .




3-44

Figur e 3-25. Classes 1 an d 2 bases for wood-cleat ed, skidded,load-bearing ba se boxes, ASTM D6256.




3-45

Table 3-21. Class 1 boxes: Requiremen ts for paper overlaid veneer panelboard and cleats

Weight contents Size of cleat s Paper over laid veneer panelboard

Exceeding Not exceeding Minimum width Min imum thickness Types 1 and 2 loads Type 3 loads

Min im um t hick nes s Min im um t hick nes s

Pounds Pounds Inches Inch Inch Inch

0 75 1-3/8 5/8 0.070 0.090

75 150 1-3/4 5/8 0.115 0.140

150 225 1-3/4 3/4 0.115 0.140

225 300 1-3/4 3/4 0.170 0.195

300 400 1-3/4 13/16 0.225 -------

Table 3-22. Class 2 boxes: Requiremen ts for paper overlaid veneer panelboard and cleats

Weight contents Size of cleat s Paper over laid veneer panelboard

Exceeding Not exceeding Minimum width Min imum thickness Types 1 and 2 loads Type 3 loads

Min im um t hick nes s Min im um t hick nes sPounds Pounds Inches Inch Inch Inch

0 100 1-3/4 5/8 0.070 0.120

100 250 1-3/4 3/4 0.140 0.180

250 350 1-3/4 13/16 0.225 0.195

F a b r i ca t i o n o f P a n e l s

When panels are fabricated locally, they are made according to information

cont ained in ta ble 3-13 an d HP MA-HP 1983. Also see PP P-B-601 const ru ction

of pan els. Even filler cleat t oleran ce and dr aina ge shall be in accordance with

PPP -B-601. Cleat arra ngement on top panels is illustra ted in figure 3-26.

When joists are required for the super-structure to hold superimposed loads,they a re selected in a ccordance with ta ble 3-23. Joist supports are required t o

be placed beneath each joist (see fig 3-27). The vertical and material supports

shall comply with the material requirements for the cleat stock, except that

the thickness shall not be less than one inch for container loads up to 1,000

pound s. For loads in excess of 1,000 poun ds, the su pports sh all be not less

tha n 2 inches. The vertical joist supports sh all be nailed to the side panels

with n ails long enough to pass t hr ough th e clinch of 1/8 inch for Gr oups II, III,

an d IV woods a nd 1/4 inch clinch for Group I woods.

Fa br i ca t i on o f Bas e Com p onen t s ( s ee fi g 3 -24)

S k i d s

Skids will be made of Group II, III, or IV lum ber. The cross section an d lengthof skids are chosen from table 3-28, based upon weight of contents and load

cond itions, as illust ra ted in figure 3-27. For boxes whose out side width

exceeds 36 inches, a thir d skid conform ing to ta ble 3-28 is added. The th ird

skid is placed equidistan t between the outer skids. At the ends of each skid,

the lower half is beveled approximately 45 degrees.




3-46

Load Bear i ng M em ber s

Load bearing members will be free of defects which could materially weaken

th em. They are selected in accorda nce with ta ble 3-25. The cross section of

load bearing mem bers for a pa rticular load is determin ed either by assum ing a

total width of such load bearing members and determining the thickness

necessary, or by assuming a thickness and determining a total width of load

bearing members.

Lumber Floor ing

Lumber flooring will be a minimum of 1-inch thick, and not less th an 4 inches

wide. Lumber is laid at right angles to the skids. The boar ds are separated

one-eight h to one-fourt h of an inch to allow for swelling and dr ain age. The

boar d ends a re placed flush with t he outer edge of the skids.

Plywood Floor ing

Unless otherwise specified, plywood used for Type I boxes shall conform to

HPMA-HP 1983, Type II, Grade 3-4, PS1, standa rd interior. The minimum

thickness shall be three-eighth s of an inch. See table 3-13. It ma y be th e full

length a nd width of the ba se, or it m ay be a centr ally located squar e piece with

th e lengt h equa l to the base width . When a full piece of plywood is used, a

drainage hole one-half inch in diameter is placed in each corner of the base.

Additional drainage holes are placed every three feet along the side of the

base. When load bearin g floorboards ar e placed over plywood pan els, at least

one draina ge hole is placed on each side of th e base between t he load bear ing

floorboards.

En d H eader s

En d headers ar e placed at th e ends of th e box. Header s are nominal 2 X 4

inches.

Ru bb i ng S t r i p s

When specified, rubbing strips shall be applied under each skid to facilitate

forklift han dling. They will pr ovide a nomina l 3-inch clear an ce for fork liftentry.

Table 3-23. Selection of joists for wood cleated, skidded, load bear ing

base boxes (joists s paced 24 inches--center to center)

Nominal joist s ize (Inches) Outside wid th of box (Inches)

None requ ired 24

1X4 25-36

2X4 37-60




3-47

Table 3-24 . Nominal sizes an d ma ximum len gths of skids for wood cleated,skidded, load bearing bas e boxes.

Weight of

Content s (Pounds)

Load

Condition1/

Nominal Sizes

2 X 4 2 X 6 2 X 8 4 X 4 4 X 6 6 X 6

Maximum Length of Skid (Feet)

0 - 100 AB

C

D

E

1616

16

16

16

----

--

--

--

----

--

--

--

----

--

--

--

----

--

--

--

----

--

--

--

101 - 200 A

B

C

D

E

16

16

16

16

16

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

201 - 400 A

B

C

D

E

11

13

8

10

13

15

16

12

15

16

16

--

16

16

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

401 - 600 A

B

C

D

E

8

9

5

7

9

11

14

8

10

14

14

16

11

14

16

16

--

16

16

--

--

--

--

--

--

--

--

--

--

--

601 - 800 A

B

C

D

E

7

7

4

5

7

9

10

6

8

10

11

14

8

10

14

16

16

16

16

16

--

--

--

--

--

--

--

--

--

--

801 - 1000 A

B

C

D

E

6

5

3

4

5

8

8

5

6

8

10

11

7

8

11

16

16

16

16

16

--

--

--

--

--

--

--

--

--

--

1001 - 1200 A

B

C

D

E

6

4

3

3

4

7

7

4

5

7

8

9

5

7

9

16

16

13

16

16

--

--

16

--

--

--

--

--

--

--

1201 - 1400 A

B

C

D

E

5

5

0

3

5

7

6

4

4

6

8

8

5

6

8

14

16

11

14

16

16

--

16

16

--

--

--

--

--

--

1/ The load condition is determin ed by the man ner in wh ich the load is applied to the skids (figure 3-27)




3-48

Table 3-24 (cont). Nominal sizes an d maximu m length s of skids for wood cleated,skidded, load bearing base boxes.

Weight of

Contents (Pounds)

Load

Condition1/

Nominal Sizes

2 X 4 2 X 6 2 X 8 4 X 4 4 X 6 6 X 6

Maximum Length of Skid (Feet)

1401 - 1600 A

B

C

D

E

5

3

0

3

3

6

5

3

4

5

7

7

4

5

7

13

16

18

12

16

16

--

15

16

--

--

--

16

---

--

1601 - 1800 A

B

C

D

E

5

3

0

0

3

6

5

3

3

5

7

6

4

4

6

12

15

9

11

15

16

16

14

16

16

--

--

16

--

--

1801 - 2000 A

B

C

D

E

4

3

0

0

3

5

4

0

3

4

6

5

3

4

5

11

13

8

10

13

15

16

12

15

16

16

--

16

16

--

2001 - 2220 A

B

C

D

E

4

0

0

0

0

5

4

0

3

4

6

5

3

4

5

10

12

7

9

12

14

16

11

14

16

16

--

16

16

--

2201 - 2400 A

B

C

D

E

4

0

0

0

0

5

3

0

0

3

6

4

3

3

4

10

11

7

8

11

13

16

10

13

16

16

16

16

16

--

2401 - 2500 A

B

C

D

E

4

0

0

0

0

5

3

0

0

3

6

4

3

3

4

9

10

6

8

10

13

16

10

12

16

16

--

16

16

--

Table 3-25. Allowable load (pounds) per in ch of width of load-bearing floor m embers

Length

between

outside

skids

(inches)

Nominal 1-inch thick boards

(lbs per inch)


(lbs per inch)


(lbs per inch)

Wood Groups Wood Groups Wood Groups

I or II III or IV I or II III or IV I or II III or IV

12 38 46 176 211 459 551

18 26 31 118 142 306 367

24 19 23 88 106 230 276

30 15 18 70 84 183 220

36 13 16 58 70 154 185

42 11 13 52 62 131 157

48 10 12 44 53 115 138

54 9 11 39 47 102 122

60 7 8 35 42 92 110




3-49

Figure 3-26. Styles A an d B cleat a rr an gement for wood cleated,

skidded, loadbearing base boxes.

Figur e 3-27. Atta chmen t of joist sup ports for wood cleated , skidded, load bea ring bas e boxes.




3-50

As s em bl y o f t he Ba s e

Depending upon the weight of the item, load condition, size and length of

skids, and whet her it is a Class 1 or Class 2 base, th e base part s are cut t o size

for fabrication. The na iling of plywood an d lumber floorin g to th e skids is

illustrated in figure 3-25.

Load bearing floor members over 2 inches thick and up to 4 inches in width

are bolted to th e skids with one carriage bolt at each end. Two car riage boltsare used at each end of load bearing floor members when they exceed two

inches in th ickness an d 4 inches in width. The load bear ing floor members ar e

fasten ed to skids with 3/8-inch car riage bolts. Load bear ing members less

tha n 2 inches in th ickness ar e nailed to the skids. Nails shall be as large as

pra cticable without splitting the piece. The end headers ar e fasten ed to the

skids with 3/8-inch car riage bolts.

As s e m b ly o f t h e S u p e r s t r u c t u r e

The assembly of the cleated plywood, cleated fiberboard, and cleated paper-

overlaid veneer panels into the superstructure shall comply with the

applicable requirements of the specifications already described.

As s e m b ly o f t h e S u p e r s t r u c t u r e t o t h e B a s e

The end and side panels are assembled to the base with lag bolts (sometimes

referred to as "lag screws"). One 3 inch lag bolt, three-eighths inch in

diameter, is placed through the lower longitudinal cleat of the side panel and

into the skid, at a distance not less than 2 inches from the end of the cleat.

The distance between additiona l lag bolts shall not exceed 12 inches. In

att aching the en d to th e header , one lag bolt is placed thr ough th e lower filler

and into the end header, at a distance not less tha n 2 inches, not m ore th an 3

inches from th e end of th e filler cleat . A minim um of two lag bolts ar e

required t hr ough each end filler cleat.

CAUTION

Lag bolts shall not be driven with a ha mmer except to star t them . They

shall be tur ned in their holes the full distan ce. If th e threa ds become

stripped in t he wood, the lag bolt is to be removed an d insert ed in a new h ole

near th e old position. A washer is placed under t he hea d of each lag bolt.

Coun tersinking of lag bolts is not per mitted.

WIREB OUND WOOD BOXES (P P P -B-585)A wirebound wood box is a resilient engineered structure deriving both

strength and economy from the substitution of steel wires for a considerable

portion of wood. The sides, top, an d bott om of th is conta iner a re sta pled to

several binding wires and are fasten ed to a framework of cleats a t each en d by

staples driven astride the end binding wires. The ends ar e nailed, stapled, or

wired to the cleat framework t o form th e conta iner.

Descr ip t ion of Box Com pon en ts ( fig 3-29)

B l ank

A blank is th e assembled pa rt s of a wireboun d wood box. The wood faceboards

of th e box are held together by wires which ar e stapled to them . Blanks ar e

"set up" to form a box.




3-51

Figur e 3-28. Load distribut ions of skids.

Figur e 3-29. Componen ts of wireboun d wood boxes.




3-52

Cleats

Cleats form the framework to which the ends of the faceboards or slats are

fasten ed. They are made with mitered or mortised an d tenoned ends

(tongued-and-grooved). Int ermediat e rows of cleats ma y be required to

reinforce unsupp orted spans.

Faceboards

Faceboards a re the th in board s tha t form t he six faces of the box. They arema de of veneer , resa wn lumber , plywood, or pa per-overlaid veneer . Their

chief function is to hold th e cont ent s of th e box in p lace.

Bi nd i n g Wi r e s

They hold the faces of the box together and carry most of the weight in the

box.

S t a p l e s

They hold the faceboard s an d cleats t o the binding wires.

Ends

The ends may be either plain, linered, or battened, according to the type of

mat erials used, the weight of cont ents, an d type of load. Only ends made from

plywood are plain.

Bat tens

They ar e pieces of wood used on t he en ds of wireboun d wood boxes to reinforce

the en ds, to reinforce th e cleats, an d to increase the stren gth of the box so that

it ma y car ry hea vy stacking loads.

L iners

They are thinner pieces of boards stapled to the ends in order to tie all parts

together a nd to stren gthen th e fasten ing section. The grain of the liner is

placed at right an gles to th e grain of th e end faceboard. They are stapled to

either t he outside or inside face of th e ends. Liners for Styles 1 and 2 boxesare always vertical; liners for Style 3 boxes are always horizontal.

S k i d s

A wirebound box has t wo skids add ed when it carries a gross weight in excess

of 200 pounds or when the gross weight exceeds 100 pounds, but the length

and width a re 48 inches by 24 inches or more. Additional skids are added if

the dista nce between them exceed 48 inches. They are secured by two rows of

nails in a staggered pat tern . PP P-B-585 stipulates other requiremen ts

concerning the addition of skids.

Cl as s e s

Class 1 Domes t icFor domestic shipments not involving sea transportation, but subject to

storage, reha ndling, or reshipmen t to domestic destinat ions. Weight

limitation is 500 pounds.

Class 2 Norm al Oversea

For off-shore and oversea shipments contemplating projected storage and

comm ercial-type han dling. Weight limita tion is 400 poun ds.




3-53

CLASS 3 MILITARY OVER SEAFor oversea shipments and handling in military supply systems, subject to

repeated rehandling and unprotected storage, and which may also be

subjected to extr eme climat ic cond itions. Weight limita tion is 300 poun ds.

If required, Class 2 and 3 boxes are preserved with the same preservative

trea tmen t a s PP P-B-621 and PP P-B-601 wood boxes.

STYLE O F BOXES

Three styles of wirebound wood boxes are used for domestic and oversea

shipment s. These styles differ primar ily in th e man ner of closur e of th e

binding wires. Ea ch style can be easily recognized in figure 3-30. Style 1 ha s a

twisted wire closure, Style 2 has a looped wire closure, and Style 3 has a

looped wire closure and has the ends reinforced with wire instead of battens.

Unless end battens are used, the Style 3 box is not recommended for Type 3

(difficult ) loads.

OR D E R I N G DAT A

Wirebound wood boxes are engineered and manufactured commercially and

are n ot made locally by militar y activities. Procurement documen ts shouldinclude the specification number (PPP-B-585); the inside length, width, and

depth to the nearest one-sixteenth of an inch; the style of box; the class of box;

the type of load; and the weight, qua ntity, and ma rking of th e content s. If

blocking or bracing is required, it is suggested that a drawing or a sample of

the item be furn ished to th e box manu factu rer.

C ONTAINER MANUFACTURER 'S I DENTIFICATION

Unless otherwise specified, each box is imprinted with the following

informat ion, which is limited t o 15 square inches a nd placed in a lower corner

of one side pa nel:

• Federal Specification PPP-B-585.

• Box manufacturer's name.• Plant location.

• Maximum weight of contents...poun ds.

• Class...box. For type...load. Style...Box.

B OX USAGE

Each box is manufactured to do a specific job. When used for the proper

maximum weight of contents, type of load, and class of use, it will afford

adequa te protection to th e item being shipped. It is importa nt th at th e

container ma nu factu rer's identification be utilized prior to packing. The

following points mu st be considered :

• In using the boxes, care should be exercised to select the box designed

for th e type of load t o be shipp ed. A Type 2 load will not be packed in

a box designed to carry a Type 1 load, and a Type 3 load will not be

packed in a box designed t o carr y either a Type 1 or a Type 2 load.

• Type 1 an d 2 loads, th e inside dim ensions of the box will be sufficiently

exact so that the contents fit snugly into the box and give support to

all its faces.

• Type 3 loads, other than bulk loads, the contents will be firmly bolted,

blocked, braced, or otherwise anchored to the frame of the box in such

a manner that shifting of the contents will not occur during handling

of the sh ipment.




3-54

E CONOMY F ACTORS

Wirebound wood box contains approximately one-half as much lumber as a

nailed wood box of the sa me size which car ries th e sam e am ount of conten ts.

Wirebound wood boxes ar e usu ally available at a lower price tha n m an y other

shipping containers of more rigid construction.

Style 3 boxes are resilient on all six faces. Items r equiring this char acteristic

in the box can use a St yle 3. Style 3 boxes ar e the most economical of th estyles. The original cost of th e box is less th an t ha t of the other styles. The

savings of time in setting up th e boxes is advan tageous. Since the a mount of

lumber in a wirebound wood box is great ly reduced, compared to other types of

wood containers, the tare weight is lower. Accordingly, the freight charges on

a given size shipment a re correspondingly lower. There is a sa ving in labor

operations due to the simplicity of assembly and the ease of closure.

Styles 2 and 3 boxes can be opened and reclosed at intermediate stages of

distribution much easier tha n other kind s of conta iners.

Wirebound boxes can be repar ied and r esused.

Figur e 3-30. Styles of wireboun d wood boxes.




3-55

SE T T I N G U P T H E B OXES

Boxes arrive from the manufacturer in a knockdown condition and are stored

knockdown unt il the time of use. each box is then set u p prior to loading of

shipment . The meth od of setting up depen ds upon th e style of th e box.

Set t in g u p of S ty les 1 an d 2 ( fig 3-31)

Lift th e sides of th e blank slight ly before folding. Fold the box by raising th e

sides at r ight angles to th e bottom. Fast en th e ends to th e side cleats using asteel na iling table or an end stapling machine. En ds are fasten ed to side

cleat s by either st aples or cemen t-coat ed and chem ically-etched na ils. Un less

other wise specified, sta ples for Class 3 use boxes are galvan ized. The length

of each fastening will be not less than the thickness of the end boards plus

three-quarters the thickness of the cleats or battens. The points of the

fasten ings will not protru de from t he cleats or bat tens, but , if driven th rough,

they mu st be clinched. The avera ge spacing of the fastenings will not exceed 2

1/2 inches.

Drive sevenpenny cement-coated or chemically-etched cooler or sinker nails

through side cleats into adjacent battens and through bottom cleat into

interm ediate batt en. Boxes ha ving both vertical and horizontal batt ens

adjacent and parallel to cleats should be fastened by nailing through bottom

faceboar ds and cleats into the batt ens only. The spacing of nails driven into

adjacent bat tens will not exceed 5 inches.

Set t in g u p of Style 3 ( f ig 3-32)

Bend u p looped end wires of end s using th e hollowed end of a bon ender . Lift

sides of the blank slightly before folding and raise sides at right angles to

bottom. Pa ss the bent end loops thr ough notches in th e cleats. Using the

tapered end of the bon ender, bend back the looped wire over and around the

binding wir e of th e side.

When batt ens ar e used on the en ds of style 3 boxes, batt ens adjacent t o batt en

cleats are nailed by driving sevenpenny cement-coated or chemically-etchedcooler or sinker nails through the bottom boards, through the cleat and into

the adjacent batten . Spacing of na ils will not exceed 5 inches. Inter mediate

battens are secured by driving one sevenpenny cement-coated or chemically-

etched cooler and sinker nail through the board and cleat into the end of the

intermediate batt en.

S t r a p p i n g R e q u i r e m e n t s

Where strapping is required, the top cleats shall be brought in contact with

the side cleats and the strapping is applied before the wires at the closing

edges ar e twist ed or looped. This elimina tes occasiona l slack which ma y

develop when st rap ping is applied after closur e is made. Stra pping is placed

as indicated in figure 3-33 wire strapping cannot be smaller than 13-gauge.

Flat stra pping cannot be less tha n 5/8 X 0.020 inch.




3-56

Figur e 3-31. Sett ing up of styles 1 and 2, wirebound wood boxes.




3-57

Figur e 3-32. Sett ing up of style 3 wireboun d wood box.




3-58

Figur e 3-33. Str ap ping of wireboun d wood boxes.

Cl osu r e o f t he Boxes

Closu re o f S ty le 1

Style 1 boxes are closed by using special tools (fig 3-34). When in ter media te

battens are used on the ends of the box, one sevenpenny cement-coated or

chemically-etched sinker or cooler nail is driven through the top board andcleats and into the end of each intermediate batten. This is done prior to

mak ing th e closures of the binding wires.

Closu re o f S ty les 2 an d 3

These styles are closed by using a Sallee closer. Per form the steps, as shown in

figure 3-35. Insert the Sa llee closer th rough th e side loop an d catch the top

loop in th e notch on the en d of th e tool. Raise th e han dle of th e Sallee closer to

slightly beyond a vertical position a nd push the top loop down a gainst t he side

of th e box. Complete closing by swinging th e ha nd le of the Sa llee closer d own




3-59

as far as possible. Drive a na il th rough the top cleat into each inter mediate

batt en. Do not nail into the ends of the batt ens tha t are adjacent to the cleats.

Note. The ap plicable tools for makin g closur es are illustr at ed in figures 3-34

and 3-35. Correct tools are available from box man ufacturer. Do not use

screw drivers, pliers, etc., because an adequate closure cannot be made and

their u se is time-consuming an d may be a safety hazar d.

PALLETS (GENERAL)


A pallet is a portable platform on which material is placed to facilitate

han dling and tr an sportat ion. This platform is genera lly a two-deck stru ctu re

which permits mechanical handling and tiering of unit loads of supplies an

equipment.

Types o f Pa l le t s

Pallets are classified as expendable an perma nent . They are also classes as

general pur pose and special pur pose.

E x p e n d a b l e P a l le t s

Expendable pallets are designed generally for one shipment and then

discarded . Their constr uction is usua lly of wood, fiberboard , or a combinat ion

of th e two. In order to be effective as one-trip pallets, they mu st be

light weight an d low in cost. When t he cost of usin g them is equalled or

exceeded by the savings realized during a single trip, they are truly

expendable pallets. Examp les of expendable pallets are illustr ated in figure 3-

36.

P e r m a n e n t P a lle t s

Perm an ent pa llets are ter med as genera l purpose an d special purpose pallets.

G e n e r a l P u r p o s e P a ll e t sThe general pu rpose pallets ar e constru cted of ha rd wood an d ar e normally 40

inches by 48 inches in size. They fit economically int o ra ilroad an d, motor

vehicles, an d tra ilers. Two general pur pose pallets are th e 4-way entr y post

pallet and the 4-way (partial) four-stringer pallet (fig 3-37).

S p e c ia l P u r p o s e P a l le t s

Pallets made of metal, which are suitable for certain heavy duty usage, are

special purpose pallets. They are more rugged and will stan d more abuse tha n

wood pallets. There ar e no fasten ers to work loose and cause dam age to

flexible containers a nd th eir contents. Pa llets mad e of aluminu m ha ve been

developed that a re light in weight. The initial cost of metal pallets is high in

compa rison t o pallets m ade of wood.




3-60

Figur e 3-34. Closing of style 1 wireboun d wood box with special tools.




3-61

Figur e 3-35. Closing of style 2 an d 3 wirebound wood boxes.

Figure 3-36. Examp les of expanda ble pallets.




3-62

F OUR -WAY P OST CON STR UCTION P ALLETS (MIL-P -15011)These pallets are available in two types: Type I (assembled) and Type II

(una ssembled). Ea ch type is ava ilable in two classe s: Class 1 (seasoned

lumber, 22 percent m aximum average moisture content); Class 2 (Unseasoned

lumber, unspecified moistu re content). There ar e four styles. Style 1 is the

general storage pallet and is of the standard 40 inch by 48 inch size, and

un less other wise specified, is const ru cted of high den sity wood. Style 1A

pallets are constructed the same as Style 1 pallets except that the size is 35

inches long by 45 1/2 inches wide. The sm aller, Style A1 pallets ar e designed

for better u tilization in int ermodal tra nsporters a nd t he fourt h st yle, style 2 is

a light-weight, air cargo pallet, 40 inches by 48 inches in size. It is const ru cted

of th e low or medium den sity woods with th ickness less th an th at for St yles 1

And 1A. These pallets provide full 4-way entry to materials han dling

equipment. As indicated in figure 3-37 nine posts are placed on t he bottom

boards with drive-screw nails conforming to Type II, Style 18, of ASTM F

1667-95. Stringers extending th e length (40 inches, Styles 1 and 2 and 35

inches for Style 1A and 42 inches for Style 1B) of the pallet are fastened to

each row of posts. The deck boar ds are na iled thr ough the str ingers and intothe posts. Style 1B pallets ar e constru cted the same as St yle 1 pallets except

that the size is 42 inches long by 53 inches wide.

FO UR-WAY (PARTIAL) STRINGE R CONSTRUCTION P ALLETS

(NN-P -71)Two-way and four-way stinger pallets are available in several types and may

be assembled or un assem bled (fig 3-37). Ea ch type is available in var ious

sizes. They are used wherever two-way or par tial four-way entr y is required

by conventional mater ials ha ndling equipment . Four str ingers made form 2

inch by 4 inch lumber are nailed or bolted at right angles to the bottom deck

boar ds. The stringers are cut out to enable fork lift entr y. The top deck

boar ds are na iled to th e stringers.

MAINTENANCE OF P ALLETSWooden pallets ar e susceptible to dama ge and mu st be kept in consta nt repair.

Broken or split deck boards must be replaced when their holding power is

impaired. Fast enings tha t work loose should be carefully repaired. When

nails must be replaced, snip off nail heads and drive into stringer or block.

Make sure that new nails do not line up with previously occupied nail holes.

It is recommended that a stock of repair parts be available for making all

repairs.




3-63

Figure 3-37. Four-way entry post and (part ial)four -stringer pa llets.




4-1

CHAPTER 4

BAGS AND SACKS

NEE D F OR BAGS AND SACKSWhile a considerable amount of the materiel furnished to the military

services is shipped in fiberboard, metal, or wooden containers, there are

man y supplies which can be m ost economically shipped in bu lk qua ntities in

bags and sacks. Items such as food products, building mater ials, some

chemicals and minera ls are effectively shipped in bags an d sacks. Bags and

sacks possess the inherent advantages of having low tare weight ratio (that

is, the ratio of the weight of the container to the weight of the contents);

being flexible; providing ease in filling and handling; requiring a minimum

storage space; and being constructed of low cost materials.

BAGS DEF INEDA bag is a preformed container made of flexible material, generally closed on

all sides except one which forms an opening that may or may not be sealed

after filling. It ma y be made of a single ply or mu ltiple plies of flexible

mat erial, or a combina tion of two or m ore mat erials such a s paper , meta l foil,

cellulose, and plastic films and textiles, any of which may be coated,

laminated, or treated to provide the properties required for packaging,

storing, and distributing th e commodity.

SACKS DEF INEDA sack often u sed as a synonym for a bag, generally refers t o heavier dut y or

shipping bags. No exact line of separa tion can be dra wn between wha t is

referred to as hea vy dut y bag and sh ipping sack. In th is section, both ba gsand sacks are discussed and may be employed to handle the same weights

an d kinds of comm odities. Usu ally, a conta iner designed to carr y over 50

pounds is considered a shipping sack.

SHIP P ING BAGS AND SACKSFor shipping military supplies, there are four flexible containers that are

app roved for use by th e DOD. These conta iner s are: cott on mailing bags (A-

A-2714); cushioned paper shipping sacks (A-A-160); burlap (A-A-1588); and

shipping bags (A-A-881).

COT TON MAILING BAGS (A-A-2714)

This description covers cloth ma iling bags with a dr awst ring closure. Cottonmailing bags are intended for packaging and mailing small miscellaneous

items.

Class i f i ca t ion

Bags sh all be of th e following types an d sizes:

Type 1 - Regular

Type 2 - Fire Retar dan t




4-2

Size A - 3 inches wide X 4 inches high

Size B - 3 inches wide X 5 inches h igh

Size C - 4 inches wide X 9 inches h igh

Size D - 4-1/2 inches wide X 8 inches high

Size E - 5-1/2 inches wide X 14 in ches h igh

Size F - 6 inches wide X 9 inches h igh

Size G - 6-1/2 inches wide X 10 inches highSize H - 7-1/2 inches wide X 18 in ches h igh

Size I - 8 inches wide X 10 inches h igh

C HARACTERISTICS

C o m p o n e n t s

Bags furnished under this description shall be made from components

meeting th e requirem ents of table 4-1.

C o n s t r u c t i o n

All seams sha ll be sewn with stitch type 401, seam type EF a-1 of FED-STD-

751, with 4 to 6 stitches per inch. Bottom an d side seams sha ll ha ve a

stitchin g ma rgin of not less th an 1/4 inch from th e edge of th e bag. The top

seam shall have a stitching margin of not less than 3/8 inch to allow for

insertion of th e dra wstring. A twine drawstr ing shall be inserted thr ough

the hem at the top of the bag so that each end of the drawstring projects not

less tha n 2 inches from the bag. The total length of th e drawstr ing shall be

not less th an t wice the overa ll width of th e bag plus an a dditiona l 6 inches. A

tag, made from cloth lined paper stock and measuring 3 ± 1/16 inches by 5-

1/2 ± 1/16 inches, shall be inserted into the bottom of the bag and shall be

sewn in place. When the bag is tu rn ed with t he seam edges inside, the tag

shall extend n ot less than 5 inches from th e bottom of th e bag. The paper

side of the t ag shall have a h ard su rface suitable for pen and ink addr essing.

D i m e n s i o n sDimensions shall be outside dimensions, expressed as overall width X overall

height . The tolera nce for each dimension sha ll be + 3/8 inches, or - 1/4

inches.


The bags shall be uniformly made, neatly trimmed, free from holes, stains,

tears, or other defects which may impair their serviceability or appearance.

The ta gs shall be firmly atta ched.

P a c k a g i n g , P a c k i n g , a n d M a r k i n g

Packaging, packing, and marking shall be as specified in the contract or

order.




4-3

Table 4-1

Component Test Requ irement Test Method

Fabr ic Breaking Force

Fa bric Count

Surface Flammability (applies

only to fabric for Type 2 bags.)

Specific

Optical Density of Smoke

(Applies only t o fabric for Type 2

bags.)

Warp, not less than 48 pounds. Filling, not

less than 35 pounds.

Warp yar ns, not less tha n 40 per inch. Filling

picks, not less tha n 40 per inch.

Average flame sprea d index, not more th an

25.

Avera ge m aximum specific optical den sity,

not more than 100.

ASTM D 5304

ASTM D 3775

ASTM E 162

ASTM E 662

Seam

Thread

Breaking Force Average breaking force, not less than 3.0

pounds

ASTM D 2256,

Option A1

Drawst r ing Breaking Force Average breaking force, not less than 24

pounds

ASTM D 2256,

Option A1

P R OC UR E ME NTBuyer s sh all specify th e following:

• Type and size required;

• Preser vation, packaging, packing, labeling, an d ma rking requ ired.

• Item Ident ifiers/Reference Part N um ber System. (For cataloging use

only.)

A-A-2714 - 1 B This example describes a regular 3 inch high bag.

Size A - 3 inches wide X 4 inches high

Size B - 3 inches wide X 5 inches h igh

Size C - 4 inches wide X 9 inches h igh

Size D - 4-1/2 inches wide X 8 inches high

Size E - 5-1/2 inches wide X 14 in ches h igh

Size F - 6 inches wide X 9 inches h igh

Size G - 6-1/2 inches wide X 10 inches high

Size H - 7-1/2 inches wide X 18 inches high

Size I - 8 inches wide X 10 inches h igh

Type 1 - Regular

Type 2 - Fire Retar dan t

CUSH IONE D P APE R SHI P P ING SACKS (A-A-160, A-A-1588)Cushioned paper shipping sacks are made of two sheets of kraft paper

separa ted by an evenly distributed cush ioning medium. They may be used

for interior or exterior packaging where insulation, water resistan ce, or light

cush ioning effect is r equired for items weighing not m ore th an 10 pounds.

CUSHIONED WITH P OST CONSUMER RE COVERE D MATERIAL

(A-A-160)

C HARACTERISTICS


The walls of the sack shall consist of 2 layers of kraft paper with a cushioned

medium such as macerated paper inserted between the layers. The outer

layer of kra ft paper shall be water resistan t. The fabricated sacks shall pass




4-4

the water resistan ce test an d the impact resistan ce test. The edge of the

inside seam sh all be located not more th an 1 inch from th e side of the sack.

D i m e n s i o n s

Dimensions of the sacks shall be outside measurements, expressed as width

by length . Dimen sions shall be as specified with a toleran ce of ± 1/4 inch.

Sack opening sh all be on t he sh ort side.


Sacks sha ll be uniform ly constru cted and free from h oles, tear s, cuts, splits,

or other defects wh ich m ight impair t heir u sefulness.

QUALITY ASSURANCE

E x a m i n a t i on o f t h e E n d I t e m F o r D i m e n s i o n s a n d Wo r k m a n s h i p

The samp le unit sha ll be one sack. The Inspection Level shall be S-2 with a n

Acceptable Quality Level (AQL) of 2.5 percent defective in accordance with

ANSI/ASQC Z1.4-1993.

T e s t in g o f t h e E n d I t e m F o r W a t e r R e s i s t a n c e a n d i m p a c t r e s i s t a n c e

The same u nit sha ll be one sack. The Inspection Level shall be S-1 with an



Wat e r Res i s t an ce Test

Two drops of water shall be placed on the outside of the sack and covered

with a watchglass. The water sh all remain on the outside of th e sack without

being absorbed for n ot less than 30 minut es.

I m p a c t R e s i st a n c e T e s t

Determine the cubic capa city of th e sack by multiplying th e th ree factors F1,

F2, and F3, together :

Cubic capa city = F1 x F2 x F3

F1 = sp ecified lengt h

F2 = 90% of specified width

F3 = 10% of specified width

Fill a graduated cylinder or similar volumetric device to 75 percent of the

cubic capacity of th e sack with d ry, un popped, popcorn. Tra nsfer th e popcorn

to the sack and seal th e open end of th e sack with pa ckaging ta pe. Drop each

sack six times from a height of 36 inches onto a h ard, u nyielding sur face such

as un carpeted concrete. The sack shall be dropped once on each face and

once on each side. If an y popcorn sp ills from th e sack, the sa ck does not pas s

the impact resistan ce test.

E x a m i n a t i on o f p a c k a g i n g , p a c k i n g a n d m a r k i n g

The sample unit for this examination shall be one fully prepared shipping

cont aine r. The Inspection Level sha ll be S-2 with an Acceptable Quality

Level (AQL) of 4.0 percent defective in accordance with ANSI/ASQC Z1.4-

1993.




4-5

REGULATORY REQUIREMENTS

The manufacturer/contractor shall certify that the kraft paper used to make

the sacks contains not less than 5 percent post consumer recovered material.

The Government reserves the right to require proof of such content prior to

the first delivery and thereafter as may be provided for under the provisions

of th e contra ct. Post consumer r ecovered mat erial is defined as paper,

paperboard and fibrous wastes from factories, retail stores, office buildings,homes, etc., which has passed through an end use as a consumer item,

including: Used corru gated boxes, old newspap ers, old ma gazines, mixed

waste paper, tabulating cards, used cordage; and all paper, paperboard, or

fibrous wa ste collected from m un icipal solid wa ste.

P ACKAGING, PACKING AND MARKIN G


order.

CUSH IONE D WITH CLOSE D CEL L P LASTIC FILM (A-A-1588)

C HARACTERISTICS


Sacks shall be fabricated from a composite material consisting of kraft paper

bonded to closed cell plast ic film cush ioning mate ria l. The composite

mat erial shall have a th ickness of not less th an 0.131 inches. The sacks shall

be fabricated so that the kraft paper forms the outside surface of the sack.

The open end of the sack shall be provided with an adhesive sealing flap

extending the ent ire width of the sack. The sealing flap shall have a str ip of

pressure sensitive adhesive, protected by a liner, extending across the entire

width of th e flap. The weight a nd test volume for each size sack sha ll be as

specified in ta ble 4-2. The fabricated sa cks shall pass the impa ct r esistance

test and t he creep test .

Table 4-2

Min imum inside Test load,

Size dimensions, inches Weight per sack, maximum pounds

000 3-3/4 x 6-1/4 0.44 oz. (12 g) 0.3

0 5-3/4 x 8-1/4 0.77 oz. (22 g) 0.8

1 7 x 10 0.99 oz. (28 g) 1.4

2 8-1/4 x 10 1.1 oz. (31 g) 2.0

3 8-1/4 x 12-1/4 1.4 oz. (40 g) 2.4

4 9-1/4 x 12-1/4 1.5 oz. (43 g) 3.0

5 10-1/4 x 13-3/4 1.9 oz. (54 g) 4.2

6 12-1/4 x 16-3/4 2.5 oz. (71 g) 7.2

7 14 x 17-3/4 3.0 oz. (85 g) 10.0

D i m e n s i o n s

Dimensions of the sa cks shall be inside measu remen ts, exclusive of th e flap,

expressed as width by length. Inside dimensions for each size, excluding th e

flap, sh all be not less tha n specified in table 4-2. Sack opening sha ll be on the

short side.


Sacks sha ll be uniform ly constru cted an d free from holes, tears, cuts, splits,

or other defects wh ich m ight impair t heir u sefulness.




4-6

QUALITY ASSURANCE

E x a m i n a t i on o f t h e E n d I t e m F o r We i gh t , D im e n s io n s , a n d W or k m a n s h i p

The sample un it shall be 1 sack. The Inspection Level shall be S-2 with an



T e s t in g o f t h e E n d I t e m F o r I m p a c t R e s i s t a n c e a n d C r e e p

The samp le unit sha ll be 2 sacks, 1 for each t est. The Inspection Level shall

be S-1 with a Acceptable Quality Level (AQL) of 2.5 percent defective in

accordan ce with ANSI/ASQC Z1.4-1993.

Impact resistance shall be verified using the test load for each size specified

in from table 4-2. The t est load for Sizes 000, 0, 1, 2, and 3 sh all consist of

dry, un popped, popcorn. The test load for Sizes 4, 5, 6, an d 7 shall consist of

bond pa per, writing paper, or pap erback books. For each size sack, th e test

load shall weigh within ± 0.1 poun d of th e weight specified in table 4-2. The

popcorn shall be placed in plastic bottles or vials which will fit in the sack

being tested. The test load ma y be distributed am ong more th an 1 bottle orvial. Cap the bottles or vials. The paper or paperback books may be wrapp ed

in paper or plast ic for ea se of insert ion a nd r emoval from th e sack. Place the

appr opriate test loads into the sack selected for th is test. Remove the liner

from th e flap, close an d seal th e sack. Drop each sack 6 times from a h eight

of 36 inches onto a hard, unyielding surface such as uncarpeted concrete.

The sack sha ll be dropped once on each face and once on each side. If an y

tears more than 1/2 inch long, extending from the exterior through to the

interior of the sack, are present at the conclusion of the impact resistance

test, the sa ck does not pass the impa ct resistance test.

Creep Tes t

Four test specimens, each 3" 1/8 inches square, shall be cut from each sack

selected for th e creep te st. Two specimens sha ll be cut from th e front face of the sa ck, an d 2 from th e rear face of the sack. The specimens shall be evenly

stacked on a piece of glass approximately 3-1/2 inches square. The bottom

specimen shall be placed bubble side up, the second specimen bubble side

down, the third specimen bubble side up, and the top specimen bubble side

down. A second 3-1/2 inch squa re piece of glass sh all be placed on top of th e

stack an d a weight sufficient t o exert a pr essure of 1.0 " 0.1 pound p er squa re

inch on the tes t specimens sh all be placed on t he top piece of glass. After 60 "

5 minutes, the vertical distance between the glass plates shall be measured

at ea ch of the 4 corn ers of th e stack with an instru ment capa ble of measuring

to 0.001 inch. The measu remen ts sha ll be taken carefully so as not to disturb

the stack. The average of these 4 measurem ents sha ll be recorded as the

initial stack thickness. The initial stack th ickness divided by 4 sha ll be

recorded as t he th ickness of th e composite mater ial. The weight shall be kepton the stack for a total of 168 " 2 hours, then the distance between the glass

plates shall be measured and averaged in the same way as was done for the

initial stack thickness. This measur ement sh all be recorded as the final stack

thickness. The final sta ck th ickness sh all be not less th an 80 percent of th e

initial stack th ickness.

Examina tion of packaging, packing an d mark ing. The sample unit for this

examinat ion sha ll be one fully prepared sh ipping container. The Inspection

Level shall be S-2 with an Acceptable Quality Level (AQL) of 4.0 percent

defective in accorda nce with ANSI/ASQC Z1.4-1993.




4-7

R EGULATORY R EQUIREMENTS

The manufacturer/contractor shall certify that the kraft paper used to make

the sacks contains not less than 5 percent post consumer recovered material.

The Government reserves the right to require proof of such content prior to

the first delivery and thereafter as may be provided for under the provisions

of th e contra ct. Post consumer r ecovered mat erial is defined as paper,

paperboard and fibrous wastes from factories, retail stores, office buildings,homes, etc., which has passed through an end use as a consumer item,

including: Used corru gated boxes, old newspap ers, old ma gazines, mixed

waste paper, tabulating cards, used cordage; and all paper, paperboard, or

fibrous wa ste collected from m un icipal solid wa ste.

P ACKAGING , P ACKING , AND MARKING


order.

P ROCUREMENT

Buyer s ha ll specify:

• Size, as listed in ta ble 4-2.

• Packaging, packing, and mar king required.

BUR LAP S HI P P ING BAGS (A-A-881)This description covers sta nda rd n ew or u sed burlap bags for u se in domestic

and overseas shipment of supplies and ma terials.

C HARACTERISTICS

Cloth

The bags shall be fabricated from jute burlap cloth conforming to the

requiremen ts in t able 4-3.


Bags sha ll be furn ished new or used, as specified.

The bags shall have open-mouth tops and shall have bottom and/or side

seams. The minimum avera ge nu mber of stitches shall be 3.0 to th e inch,

machine sewn a nd of stitch type 301 or 401 of Fed. Std. No. 751. The ra w

edges of the bag shall be sewn with export seams, such as those in Fed. Std.

No. 751, SSd-1. Seams sh all have a break ing load of not less tha n 80 percent

of the brea king load of the bur lap from which th e bags are m ade. Raw top

edges of bags shall be hem med. Selvaged edges sha ll be sewn with flat

seams, and r aw edges with export seams.

The size or capacity of the bags shall be as specified in the contract order.When specified, bags shall be suitable for subsistence items. Ea ch ba g shall

be fur nished with a polyethylene liner inser ted. The liner sha ll have a Water

Vapor Transmission Rate of now more than 15g per m 2 per day. The liner

shall extend not less tha n 3 inches beyond t he top of th e burlap.




4-8

Table 4-3

Fa bric Count

Minimum

Yarn s per inch

Maximum

Weight, per linear yar d

by 40 inch width

(+8, -2 percent )

Warp

Filling

8

8

11

11 7.5 ounces


Bags shall be clean, dry, and free of holes, tears, frayed threads, objectionable

odors, or foreign ma tter impregna ted in or a dhering t o the sides of the bags.

The bags sha ll be free from other defects which may affect serviceability. If

mended, there shall be no more tha n t wo mends per bag, and th e maximum

size of each mend sha ll not be more t ha n 2 inches.

QUALITY ASSURANCE

Tes t i ng o f Bur l ap C l ot h

The bur lap cloth sh all be tested in accordance with t he m ethods listed below.

The sa mple un it sha ll be one r oll of cloth. The In spection Level sha ll be S-2with an Acceptable Qu ality Level (AQL) of 2.5 percent defective in accorda nce

with ANSI/ASQC Z1.4-1993.

TESTS METHODS

Fabric Count ASTM D 3775

Weight ASTM D 3776

Breaking Load ASTM D 1682 (Grab Test)

Tes t i ng o f Po l ye t h y l ene

The polyethylene shall be tested in accordance with ASTM Method F 372,

Water Vapor Tran smission Rate. The sample unit shall be one roll of

polyeth ylene. The Insp ection Level sha ll be S-2 with a n Acceptable Quality

Level (AQL) of 2.5 percent defective in accordance with ANSI/ASQC Z1.4-

1993.

Examination of the end item for defects in workmanship, size, or capacity.

The sample un it shall be one bag. The Inspection Level shall be S-2 with an



T e s t in g o f t h e E n d I t e m F o r S e a m S t r e n g t h

The sam ple unit sh all be one bag. The In spection Level sha ll be S-1 with an


ANSI/ASQC Z1.4-1993. Ea ch seam of th e sample un it shall be test ed inaccordance with ASTM Standa rd Test Method D 1682, Gra b Test. The test

specimens shall be cut so that the seam to be tested is in the middle of the

specimen, para llel to the 4 inch sides. One determ ination sha ll be made on

each seam of the sam ple un it. Breaks in the fabric outside the seam ar ea,

including jaw breaks, are acceptable provided they yield breaking loads in

excess of 80 percent of the br eaking load of the burlap. Any seam wh ich h as

a breaking load less than 80 percent of the breaking load of the burlap from

which t he bags ar e made is a defect.




5-1

CHAPTER 5

PAILS AND DRUMS

DESCR IP TION, CLASSIFICATION, AND SELE CTION FACTORS


P a i l s

Pails are cylindrical containers made of metal or plastic, with or without a

bail ha nd le. They have a capa city of 1 to 12 gallons. Meta l pails are

constru cted of 20 gage or h eavier metal. The sides and bottoms of the p lastic

pails are integral units having a minimum thickness of 0.045 inches and

designed so they can be easily stacked. Pa ils may have fixed heads

employing pour spouts of various designs or have full removable heads.

D r u m s

Drum s a re cylindrical, straight-walled conta iners made of meta l plastic fiber

or plywood, or a combina tion of th ese mat erials. Dru ms ma y be provided

with r olling hoops pressed or expanded from th e body of the dr um, or I bar s

welded to th e body. Dru ms ha ve fixed or removable heads.

Note. Can s are lightweight containers made of meta l, paper boar d,

pulpboar d, or a combinat ion of meta l and paper board or pulpboard. Since

cans usually are associated with unit packaging, information concerning

them is found in FM 38-700.

C LASSIFICATION Pails and drums are classified as to usage, that is, interior or exterior

containers, an d reusa ble an d nonreu sable conta iners. They are also

classified as to composition--metal and nonmetal.

I n t e r i o r a n d E x t e r i o r C on t a i n e r s

Interior

Inter ior container s a re covered in FM 38-700.

Exterior

These conta iners consist of pails, reusable type meta l containers, a nd d ru ms.

Exterior containers ar e designed to withsta nd rough usage. They may be

palletized for convenience in handling.

R e u s a b l e An d N o n r e u s a b l e C o n t a i n e r s

Reusable

Certa in meta l cont ainers and drum s ar e designed for reuse. The reusable

type is very convenient for the ret ur n shipment of repaira ble items. This

feature is particularly advantageous in cases where repairable instruments

or accessories can be packed for shipment to the maintenance overhaul

activity in the container in which the replacement item was received.




5-2

Multiple trip pails and drums may, under certain conditions, be refilled and

reused for t he sh ipment of liquid, powdered or gra nu lar commodities.

Nonr eus ab l e

Single-trip containers usually are discarded after their first use. One type,

the strippable drum, is filled with a hot liquid which solidifies after cooling.

At destinat ion, the drum is torn away from the enclosed product. Othersingle-trip containers, designed of light gage metal, are discarded after the

first trip because of Department of Transportation (DOT) Regulations, or

because the general physical condition of the container would not warrant

another trip.

M et a l an d N onm e t a l Con t a i n er s

Pails and drums are made from metal, although some may be made from

fiberboar d. The most common met al used for drum s is mild steel. Some

drums, however, are made of aluminum, nickel, stainless steel, various

alloys, or plast ics.

USE AND SELECTION F ACTORS

Us e

A wide range of items and commodities are adaptable for shipping in pails

and dr um s. Liquids, semiliquids, semisolids, granu lar, flaked, and powdered

mat erials, and solids ma y be shipped in specified types of these conta iners.

Fragile items and precision instruments may be given the high degree of

protection th ey require by the use of cans or dru ms. Ha zardous mat erials,

such as corrosive liquids, flammable solids, flammable liquids, and acids

which cannot be shipped in any other type of container may be shipped in

appr oved types of pails and dru ms.

Selec t ion

When selecting a pail or drum, it must be remembered that these containers

are stru ctu rally rigid in design an d are dustpr oof. They may also be

waterproof or water-vaporproof. They are easy to mark and afford excellent

physical protection of conten ts during shipment an d stora ge. Pails and

drums may be less susceptible to pilferage than some other types of

containers. Care must be tak en when selecting conta iners. This is

par ticularly tru e when selecting a cont ainer for sh ipment of dan gerous items;

it is also tru e when selecting the corr ect conta iner for other items. For

example, a squar e item in a cylindr ical conta iner ta kes about 1-1/2 times th e

cube required for the same item when packed in a squa re container. In

addition to the loss of valuable cube, excess dunnage is required to fill the

voids when a conta iner of the wrong sha pe is used.

Note. Containers used for shipment s of ha zardous mat erials can n ot be madein accordance with the Department of Transportation (DOT) Specifications

after 1 October 1994 and may n ot be used for sh ipment a fter 1 October 1996.

At that time, all containers for Hazardous Materials must be made in

accordan ce with th e United Na tions Specifications. However, packages filled

prior to October 1, 1991, conforming to old requirements, and marked with

"INHALATION HAZARD" as appropriate, may be offered for transportation

and t ran sported unt il 1 October 2001.




5-3

METAL SHIP P ING AND STORAGE DR UMS (MIL-D-6054)


These reusable steel shipping and storage drums are fabricated of 18 to 22

gage steel and incorporate a full removable (recessed or dome style) cover.

Bolted-ring or lever lock closures are used to seal the cover onto the drum

body (fig 5-1). Gask ets for th e covers may be tu bula r or solid. The covers,gaskets and locking rings are interchangeable within each diameter group.

Rolling hoops, which increase the strength, rigidity, and ease of handling,

also provide the means of anchoring internal dunnage through the use of

split expan ding steel rings wh ich fit int o th e grooves (fig 5-2). When pr operly

sealed, the d ru ms provide a highly effective water -vaporproof container , th us

affording a degree of protection suitable for Method 40 and Method 50

preservation.

Figur e 5-1. Bolted rin g and lever actua ted type closur es (MIL-D-6054).




5-4

C LASSIFICATION

The drums are available in various capacities ranging from 3 to 80 gallons,

and from 40 to 250 poun ds gross weight. The dru ms a re available with inside

diameters ranging from 10.5 inches to 30 inches, and inside usable heights

ran ging from 8.08 to 41.12 inches. The capacities an d dimensions, which a re

available in different combinations, are specified in Military Standards

MS27683 and MS27684.

USE

These metal drums are intended to be used for storage and shipment of

military material . Drums are r equired by test to withstand intern al pressure

of 15.0 pounds per square inch (psi), which will allow them to be used for

packing of hazar dous mater ials for tran sportat ion by military aircraft. These

drums are also used as overpacks for shipments by air of containers which

will not meet 15 psi. All size dru ms ar e suita ble for all meth ods of

preservat ion wher e a rigid container is specified. The use of dru ms ar e

affected by the following factors:

S i z e a n d C a p a c i ty

There is no specified rule for the selection of a container for a particular item.it is obvious, however, that a container will be selected which will be

adequate to contain the item and its blocking and cushioning, yet allow

sufficient clearance between the item and the container, or between the

blocking and th e container walls, to prevent da mage to the item when th e

dru m is ha ndled roughly. The cont ainer must n ot be too large, as this will

involve the use of extra spa ce an d weight. This is a disadvant age when a

large nu mber of such dru ms ar e to be shipped or stored.

Figur e 5-2. Int ern al locking rings in position (MIL-D-6054).




5-5

I n t e r na l Lock i n g R i ngs

The split steel locking ring is designed to fit snugly within the rolling hoop of

a m etal conta iner a nd provide a circular flange sup port for interior blocking

(fig 5-3). Car e must be used in t he design of th e inter ior blocking or oth er

fitt ings to pr event displacemen t of th e locking rin g when loaded. Without

some safety device, the locking ring may be loosened by rough handling of the

container du e to th e load imposed on th e ring. Figure 5-3 illustra tes a safetyrin g ma de of plywood. If th e item being packed precludes th e use of a safety

ring, the same function may be performed by using three blocks equally

spaced around the internal locking ring and secured to the dunnage by

screws. This perm its the rem oval of th e blocks for unpa cking.

Cup -Type Inser t s

The cup-type meta l insert was developed primarily as a m ount for gener ators

and starters for metal container packing, but it may be adapted to other

items. Figure 5-4 shows the meta l cup, with plywood fasten ed to the two

ends to aid in blocking while figure 5-5 shows the cup in position, anchored

between the locking ring and t he conta iner cover. The nu merous bolt h oles

thr ough th e cup allow it to be bolted to various items as r equired.

Figur e 5-3. Use of inter na l locking rin g (MIL-D-6054).




5-6

Figur e 5-4. Cup-type met al inser t (MIL-D-6054).

Figur e 5-5. Cup-type ins ert locked in place (MIL-D-6054).

Crate-Type In ser t s

The cra te-type meta l insert is shown in figure 5-6. In use, the item being

packed is bolted to two adja cent side member s. Plywood disks on the end s of

the insert provide some cushioning. The base of th e item packed will be

insulated from the insert with barrier material conforming to MIL-B-121,

Grade A, to prevent the possibility of corrosion from reaction of two

dissimilar meta ls. The maximum weight of the packed item should not

exceed 25 pounds for the 10-1/2 inch diameter insert, or 30 pounds for the 13

13/16 inch insert.




5-7

Figur e 5-6. Item ins ta lled in cra te-type insert (MIL-D-6054).




5-8

Cl os u r e

There ar e two styles of closure for these drum s. They are th e bolted ring

closur e an d th e lever activated locking closure. Closur es ar e ma de in one of

the following ma nn ers:

• Bolted-rin g closure. The closure ma y be made in two ways. A device

may be used which encircles the locking ring and applies pressureun iformly ar ound the circumference of the ring. The closur e is

effected by tightening the bolt and nut after uniform pressure is

applied at all points around the ring. Care should be taken th at t he

gasket is properly seated in the groove of the cover prior to closure.

Alternately, closure may be made by tightening the closure bolt (fig 5-

7). The locking ring is tapped a t various points a bout th e closure r ing

while the closure bolt is being tightened. The tighten ing is continued

until at least a minimum torque of 6 foot-pounds plus or minus one-

ha lf is applied. In lieu of th e specified torque indicat ing device,

closur e of an exterior m etal conta iner h aving a slotted-head bolt m ay

be accomplished by using a common screwdriver having an overall

length of app roximat ely 17 inches. If th is procedur e is followed, a

spot check of torque with a torque indicating device should be madeto assure adequa te tensioning. Drum s used for shipping commodities

by Parcel Post will have the bolt end and protruding edges of the

closure rin g wra pped, ta ped, cushioned or otherwise securely covered

to prevent damage to postal employees, mail bags, and other

conta iners dur ing shipment . Cont ainers shall be overpacked in

fiberboar d boxes when this extr a p recaution is considered n ecessary.

When overpacked, containers shall be secured within the fiberboard

box with fiberboar d or other su itable dunn age.

Figur e 5-7. Tapp ing locking ring while tighten ing bolt to insu re

an effective seal (MIL-D-6054).




5-9

• Lever actua ted locking closure. When specified in the cont ra ct or

purchase order a lever actuated type locking ring may be used

instead of the n ut a nd bolt type locking ring. Use may be ma de of a

device which encircles the locking ring and applies pressure

un iformly about th e circum ference of th e locking ring. The closur e is

then affected by closing the locking lever and then the wire and lead

seal lever which locks th e locking lever in position. When th eencircling device is not available for use, tension is applied by the

locking lever and the ring is tapped repeatedly around the

circumference until the ring is seated and the lever is in a locking

position. The lever is th en locked into place by the wire a nd lead sea l

lever lock.

Sea l i ng

Sealing of the conta iner is effected by mea ns of a wire a nd meta l seal which is

app lied after t he closure is complete. Drill 3/32 inch diam eter h oles in each

locking rin g lug if th ey ar e not alrea dy predrilled. The sealing wire is

inserted through the holes and the loose ends are twisted together tightly,

after which th e seal is crimped over the t wisted ends of the wire.

R e p a i r a n d R e u s e

The components of the metal shipping and storage drums are repaired and

reu sed a s follows:

• Conta iners, cover, ring, and gasket. Due to the welded constr uction

of an exterior type metal container, dents are considered repairable

even though a seam or joint is involved. Dents a re rem oved, painted

surfaces retouched, an d the container r eused or retu rn ed to stock. If

the container is distorted beyond practical repair, or has a dented or

otherwise damaged sealing lip, it is unfit for further use and should

be handled accordingly.

• Metal insert s and du nn age. It is not norma lly considered advisable to

repair met al inserts or dunn age, due to the fact tha t once distorted or

deformed, the metal insert would probably be weaker if bent back

into the origina l sha pe, and th us be incapable of affording the

necessary protection. If bent back an d reinforced, the spring ra te of

the material might be greatly changed, thus transmitting any shock

directly to the pa rt to be packed and causing dam age. However, in an

emergency they may be repaired under competent engineering

supervision. Immediat ely upon removal of an item from a metal

insert type mount, the interior locking rings and metal inserts must

be retur ned to stock, un less required for immediat e reuse. Al inserts

and interior locking rings are stocked and handled as separate items,

an d never as component par ts of th e container a ssembly.

METAL DRUMS (STANDARD ) (MISCELLANE OUS)


Metal dru ms are cylindr ical, single-wall shipping conta iners with a capacity

which usually ranges from 12 to 110 gallons, 55 gallons being the most

common capacity. Metal drums are equipped with rolling hoops which

provide additional str ength to the side wall and pr ovide for ease of handling.

The r olling hoops may be pa ra llel to each oth er or be offset t o facilita te closer

nesting for palletization and carloading. Metal drums may have full

rem ovable hea ds or tight hea ds (fixed) (fig 5-8). A dr um wit h a t ight h ead is




5-10

provided with a 2 inch diamet er bun g and 3/4 inch diameter vent h ole for

filling and emptying. These openings may be on the drum h ead or in th e

dru m body. Drum s may be unlined or lined with lacquer, varnish, enamel

and p lastics, rubber, lead, or aluminu m.

C LASSIFICATION

The DOD uses many kinds of drums for the shipment of various materials.Listed in ta ble 5-1 is th e Feder al specification n umber an d t itle (PP P-D-729)

and the DOT specification number and title. Figure 5-8 shows the type of

drum classified in Federal Specification PPP-D-729 and the corresponding

DOT-5B. DOT designates the DOT 17E and DOT-37A drums as single-trip

containers.

Figur e 5-8. Types of dru m closures an d typical ma rk ings for

domestic drums (PPP-D-729).




5-11

Table 5-1. Specifications an d Titles of Meta l Dru ms .

Federa l specification num ber and title DOT specification, number and title

PPP-D-729 drum, metal, 55 gallon (for

shipmen t of noncorrosive mat erials)

Type I..............................................................(Class A-Closehead, Class B-Openhead)

Type II.............................................................

Type IV............................................................

Type V.............................................................

Type VI............................................................

Type VII...........................................................

DOT-5B Steel barr els or dru ms. Removable head containers whichwill pass all required tests ar e auth orized.

DOT-17E Steel drum s, single trip container. Removable head

containers not authorized.

DOT-17H Steel drum s, single trip container . Removable head

required.

DOT 5A - Straight side, unlined steel for acid and corrosive liquids.

DOT 5C - Straight side, corrosion-resistant steel for acid and

corrosive liquids.

DOT 5D - Closehea d str aight side, lined steel for acid an d corrosive

liquids.

USE

The tight (fixed) head drums are primarily used for the shipment of liquids.

Emptying may be through either the filler or vent hole, although the filler

hole is most commonly utilized. A spout ma y be affixed to th e thr ead ed

portion of th e hole to facilitate emptying. A pum p, either h an d or

hydra ulically operated, may be utilized in th e hole. Greases, dry powdered,

flaked or granular materials, etc., may be shipped in a full removable head

dru m. The full removable head dr um pr ovides th e easiest access to th e

contents.

R E U S EMost metal drums are initially filled at the manufacturer's plant and are

reusa ble except for single-trip cont ainers. When empty, the dru ms ma y be

ret ur ned to dest inat ion for refilling. If refilling is done by th e initia l user ,

care should be taken not to reuse drums which have been used to ship

hazardous materials, until such drums are cleaned and tested in accordance

with UN recommendations. Failure to do so may create a serious health

hazar d. When filling dru ms with dan gerous mat erials, only UN

recommen ded type dru ms may be used for th at commodity. The dru m

specification number, the name, initial, or symbol of the manufacturer; the

letters "US" to indicate tha t th e drum is the property of the Governmen t; the

letters "STC" if the drum is a single-trip container; and a numerical

indication of th e th innest gage of metal u sed in t he constr uction, th e capacity

of the drum in gallons, and the year of manufacture are embossed on thebottom of th e dru m (fig 5-8). For exam ple, 18-55-74 mean s tha t dru m is 18

gage metal, 55-gallon capa city, and was mad e in 1974. When filling th e

dru ms, the conten ts ma y not exceed the m ar ked capacity minu s 2 percent for

outage.




5-12

FIBE R DRU MS (P P P -D-723)


Fiber drums are cylindrical shipping containers with bodies made of

fiberboard, either lapped or parallel wound (convolutely) in the form of a

hollow cylinder. They may be eith er single un it or telescopic body type. The

heads ar e of meta l, wood, plywood, or fiberboard. There are ma nychara cteristics of fiber dru ms wh ich give them advan tages over other t ypes of

containers. Included am ong these are cleanliness, dura bility, low uniform

tare weight, retard temperature fluctuation, easy opening and closing, water

and moisture resistance, stackability, easy handling, product protection and

wide ra nge of diameter s and heights. Fiber drum s are easily opened and

reclosed.

C LASSIFICATION

Fiber drums are available in the types, grades, and classes shown in table 5-

2.

USE

The intended u ses are shown in ta ble 5-2. The other factors covered by this

para graph m ust a lso be observed.

Dom es t i c Type ( Type I )

Fiberboard drums covered by this specification are intended for use as

domestic shipping containers. Grade A drum s are for dr y or solid mat erials.

Class 1 regular construction should normally be used; class 2 foil laminated

should be used for highly hygroscopic materials needing a barrier, such as

desiccan ts. Use of grade B dru ms should be limited to semisolid ma terials

having a consistency similar to asphalt, lubricating grease, petrolatum,

refractory cement, caulking compounds, roof coatings, adhesives, textile

sizing, and food produ cts such as jellies and fond an ts. The consist ency of

asphalt materials and lubricating greases should not exceed 350 units when

measured in accordance with method 311.6 of FED-STD-791 (ASTM D 217).

Class 2 is normally used when high moisture barrier is required or when the

type I, grade A, class 2 is supplemental by the aluminum liners it may be

used to deter electrostat ic charges and pr event explosion. Grade C dru ms ar e

for hot-poured materials that solidify on cooling and should be limited to

materials poured at temperature not exceeding 400oF. Grade E drums are

for nonregulated liquids or articles in liquids.

Type I , Gr a de D

This is also intended for norma l overseas shipment . When substitu ted for

type II drum s, the dru ms sha ll be mark ed type II, overseas type (nonweather

resistant).

T y p e I I O v e r s e a s (N o n w e a t h e r R e s i st a n t ) Fiberboard drums covered by this specification are intended for use for

normal overseas shipment where numerous handling and storage at

destination are not anticipated.

Type I I I Ove r s ea s (Wea t h e r Res i s t an t )

Fiberboar d dr ums covered by th is specification a re int ended for un protected

weather exposure usage for added protection in high humidity or outdoor

storage environment.




5-13

E x c e p t io n a l R e q u i r e m e n t

Exceptional commodities, especially dangerous articles (hazardous material),

may require better material and construction requirements than are covered

by th is specificat ion.

C o m p l ia n c e M a r k i n g

In addition and adjacent to the drum manufacturer 's markings required byUniform Freight Classification, National Motor Freight Classification or DOT

rules or regulations, each drum is stamped or printed in black capital letters

not less tha n 3/16 inch in h eight with informa tion concerning t he t ype, class,

gra de, specificat ion nu mber , etc. For examp le, th e informa tion for the Type I

dru m is sh own below:

Type I

(DOMESTIC TYPE)

COMPLIES WITH FE D. SPEC. PP P-D-723J

FOR DOMESTIC SHIPMENT _____________

GRADE_______CLASS__________________

MAX. WT. OF CON TENTS ___________LBS.

MAX. CAPACITY OF CONTENTS ______GAL.

In addition, Grade D drums shall have stenciled or printed on the cover and

side wall in letters not less than 3/4 inch in height, the following

precautionary markings:

STAND ON EN D

KEEP COOL AND DRY

Only contents of the type, grade, and class as indicated in the compliance

mar kings are to be placed in these drum s. The weight an d capa city must a lso

conform to th ese requiremen ts.

Table 5-2. PP P-D-723 Fiber drum s

Types, grades, a nd classes. Fiber dru ms covered by this specification

shall be of the following types, grades, and classes, as specified.

Type I

Type II

Type III

- Domestic (nonweat her r esistant )

- Overseas (nonweather resistant)

- Overseas (weather resistant)

Grade A

Grade B

Grade C

Grade D

Grade E

- For dry an d solid ma terial (applicable to all types)

- For sem iliquid ma terial (applicable to all types)

- For hot poured materials that solidify on cooling (applicable to types I and II only)

- For rolled or cylindrical items (applicable to types I and II only)- For liquids or articles in liquid - nonregulated (applicable to all types)

Class 1

Class 2

Class 3

Class 4

Class 5

- Regular constr uction (applicable to only types I and III grade A dru ms)

- Foil laminat ed constr uction (applicable to only types I and III grade A dru ms)

- Integral plast ic lining (applicable to only grade E dr ums)

- Semi-rigid plastic component (open h ead loose liner applicable to only grade E drum s

- Molded rigid one-piece plastic component (closed head liner) applicable to only grade E drums




5-14

Cl os u r e

The closure of fiber drums must be such that they may be opened and

reclosed by ha nd or simple tools. These ar e thr ee types of closures wh ich ar e

comm only used. They ar e th e friction-type or telescopic slip on covers, wh ich

are secured with pressure sensitive tape, lever-activated locking bands, and

th e m eta l clip or lu g closur e (fig 5-9).

Figur e 5-9. Types of fiber dr um closures (PP P-D-723).




6-1

CHAPTER 6

CRATESINTRODUCTIO N TO CRATES

NOMENCLATURE AND R ELATED TE R M S

Crates are rigid containers constructed of structural members fastened

together t o protect the conten ts. Crat e design involves num erous nam es and

terms which must be defined if the construction of crates is to be explained

without confusion. When the na mes of th e separat e component s are known,

although they differ in various specifications and drawings, their functions

and r elationsh ip to each oth er are more easily un derstood. In order tha t both

general and detail design requirements may be clearly understood, reference

to items des cribed in ASTM D 996 an d below is recommen ded.

N o m e n c l a t u r e

Baf f l e

A piece of plywood, wood, or m eta l placed over ven tilat ion holes to d eflect air

or water entering the crate.

B o t to m S h e a t h i n g

Boards na iled to the bottom sur face of th e fra me mem bers of a sill base. Also

kn own as flooring.

Br i dg i ng

Members of the same depth as joists or sills placed at right angles to theintermediate longitudinal or crosswise sills or headers to prevent lateral

tu rn ing or buckling of th e joists or sills.

Cleats

Auxiliary reinforcements for plywood pan els placed between vertical st ru ts to

strengthen the pan el.

Covered Cra te

A crate with open-type frame with an outside covering of plywood or paper-

overlaid veneer.

Cr a t e Bas e

The bottom load bear ing unit of a crat e.

Crate Cover in g

A lightweight material fastened to the frame of an open crate to give more

positive weather proofing tha n is offered by an open crat e an d shr oud.

Diagonals

Frame members positioned between parallel frame members and placed at

angles of nearly 450 to the latter.




6-2

Diagon al Floorboard s

Usua lly 1-inch board s, cut at 450 angle to the skids and placed between the

forklift areas.

En d Fr am e M em ber s

Members of the top panel of an open crate, placed crosswise at each end of

the top.

En d S i l l s

Members forming the ends of a sill frame.

Fi l ler S t r ips

Boards placed across the ends of thin, nonload bearing floorboards which fill

the space below the lower frame m ember of the sides.

Floor Mem bers

Board s an d timbers nailed or bolted to th e top of the skids form ing a plat form

for the contents a nd a bottom closur e for t he crat es.

Forkl i f t Area Area extending 42 inches in from ea ch end of th e crate, u sua lly floored with

2-inch boards.

Fr am e Member s

Those wood members which form th e fun dam enta l structu re of the crat e.

Gus s et P l a t e

A square piece, usually plywood, placed at the junction of the diagonals for

reinforcement.

Ha nger , Meta l

Metal strapping formed in a manner to support intermediate sills on a sill-

type cra te or joists of the t op.

Head ers or En d Cross Mem bers (Open Crate)

Cross members attached at the end of the skids which hold the skids

together . Also longitu dina l mem bers at each end of top joists.

Hor i zonta l Braces

Members positioned between struts and parallel to upper and lower frame

members of the sides or en ds.

Hor i z on t a l Top Br ac i ng J o i st Su ppor t

Horizontal member attached to the frame members in which the top joists

rest.

In term edia te Crosswise S i l l s

Fu ll length mem bers located between the en d sills an d par allel to them.

I n t e r m ed i a t e Fr am e M em ber s

Members of the t op panel of an open crate located between an d par allel to the

side fra mes of the t op.




6-3

I n t e r m ed i a t e Long i t ud i na l S i l l s

Full length mem bers located between the side sills an d par allel to them.

I n t e r med i a t e Sk i d s

Full length beams located between an d par allel to the skids.

J ois ts Members extending across the crate that support the top and prevent

cru shing when grab hooks are used.

J o i st s Su ppor t s

Members, usua lly 2 x 4, nailed to the frame un der each joist and exten ding to

th e floor.

Ki ck B l ock s

Short m embers at tached at th e junction of the corner post an d upper or lower

edge member. They are used on end pan els ha ving no braces or th ose with a

single diagonal brace.

Lag Bo l t Re i n f o r ci ng S t r ap Galvanized strapping drilled to take lag bolts and nailed to the inner face of

the sheath ing at th e center l ine of the skid and header.

Load Bear in g Floor Mem bers

Heavier or reinforced floorboards used to hold the concentrated weight of the

cra te load.

Lower Fram e Member

Horizontal frame member at the lower edge of the side and end panels.

Formerly called lower edge member.

Open Cr a t e

A crat e formed of frame m embers only, without exterior shea thin g att ached.

Re i n f o r ced S t r a ps

Metal stra pping applied at th e corners or base corn ers to reinforce and fasten

the panels together.

Ru bb i ng S t r i p s

Board s na iled to th e un derside of skids or bottom sh eath ing.

S h e a t h ed C r a t e

A crat e in which th e frame m embers a re completely covered with sheat hing.

S h e a t h i n g Material such a s plywood, lumber , or fiberboard na iled to th e frame of a crat e

across all openings to add stren gth t o the crate, or t o prevent loss of contents,

pilferage, or ent ry of dirt, wa ter, etc., int o the crat e.

S i d e Fr am e Member s

Members of the top panel of an open crate, placed lengthwise of each side of

the top.

S i d e S i l ls

The mem bers forming t he sides of a sill base crate.




6-4

S i l l s

The continu ous frame m embers of a sill base.

S i l l Bas e

A crat e which ha s its fram e members (sills) built on th e inside of th e crate to

which th e bottom sheat hing is att ached.

S i l l Br i dg i ng

Members of the same depth as the sills placed at right angles to the

intermediate lengthwise or crosswise sills of a sill base to prevent twisting or

buckling.

S k i d s

The out side longer beams of a skid base which sup port the weight of the

crate and contents.

S k i d B a se

A cra te base wh ich h as its longer beams on t he outside.

Sleeper Reinforcing members secured to the underside of the floorboards, at right

angles to th e floorboards t o provide secure a nchorage for the item.

S p a c e r s

Members which position th e end s of joist or sills.

S p r e a d e r s

Members placed at right angles to the floorboards, between the item and the

floorboard s, to distribute t he load over a wider area .

S l i n g No t ches

Open spaces between th e ends of the r ubbing strips and t he ends of th e cra te,

or cuta way sections at the ends of th e skids.

S t r u t s

Vertical fra me members between t he upper an d lower frame mem bers.

Top J o i st Spa cer s

Short members nailed between the top joists, to the inside face of the upper

fra me member s, which a ct a s end bridging.

T o p S h ea t h i n g

Board or p lywood forming t he closur e of th e top.

Upper Fr am e M em ber or Upper Ed ge M em ber Horizont al fram e member at th e upper edge of th e side an d end pan els.

R e l a t e d T er m s

Ac t ua l S i z e Lum ber

The tr ue dimen sion of a piece of lumber a s mea sured with a scale.

Cen t e r o f Ba l a nce

The point along the length of a crat e at which it would balance on a fulcru m,

placed at right a ngles to the skids of sills.




6-5

E n d G r a i n N a i l in g

Nails driven pa ra llel to the gra in of the wood.

Gross Weigh t

Total weight of the crat e an d its conten ts when ready for sh ipment.

Ho l ddowns Devices constructed of wood or metal, used to secure the item to the base of

the crate.

Liner

Waterpr oof barr ier mater ial placed between th e fram e and th e sheath ing.

N e t Weight

The weight of the item a lone, excluding dun nage, wra ppings, or containers.

Nom i na l S i z e Lum ber

Dimension of lumber before it is dressed.

Over dr i v i ng

Driving n ails into wood so that the heads sink below th e sur face of the wood.

S i d e G r a i n N a i l in g

Nails driven at right a ngles to the grain of the wood.

Ta r e W ei gh t

The weight of the crate, including dunnage, holddowns, and packing

materials.

Under dr i v i ng

Driving nails into wood so that the heads protrude above the surface of the

wood.

C LASSIFICATION OF C RATES

Crat es are grouped into several categories. They may be open or sheat hed

(fig 6-1). Cra tes may be nonde moun ta ble, single trip cra tes of na iled

constru ction, or bolted, reusa ble, demount able crates. Crat es may be

designed for domestic use only, or for both domestic and oversea shipments.

Some crates are designed for general use and others are constructed in

accorda nce with a specificat ion for a par ticular item. Of cour se, th e

classification of a crate may include a combination of several of the above

factors.

O p e n C r a t e s An open cra te is a conta iner formed of fra me m embers only, without exterior

sheat hing atta ched. When plywood or paper-overlaid veneer is used to

provide additional weather protection, they may be called covered crates as

opposed to sheat hed crates. The open crates discussed in th is section are th e

most widely used (fig 6-2, 6-3, and 6-4).

S m a l l O p e n C r a t e s

Small open crates may be subdivided into the following categories:




6-6

Figure 6-1. Open an d sheath ed crat es.

S h a l lo w C r a t e s

These crates are normally not more than 12 feet in length, 4 feet in width,

and 2 feet in height, as illustr ated in figur e 6-2. The net weight of conten ts

should not exceed 1,000 poun ds. However, ther e are exceptions to these

requiremen ts wh ich a re explained in the footnote of table 6-3.

L i gh t w e i gh t C r a t e s

These crates are designed for net weight of contents not exceeding 250

pound s. The size is limited t o 4 feet in length , 3 feet in width , and 3 feet in

height (fig 6-2 a nd 6-3).

M e d iu m We i gh t C r a t e s

Crates in this classification are normally designed for a net weight of

cont ent s not exceeding 1,000 pound s. The size is limited to 6 feet in lengt h, 4

feet in h eight, a nd 4 feet in width (fig 6-2).

Hea vy Wei gh t Cr a t e s

These crates are normally designed for a net weight not exceeding 4,000

pound s. The size is limited t o 32 feet in length , 6 feet in width, an d 10 feet in

height (fig 6-2, and 6-3, Type V).




6-7

Figur e 6-2. Styles of open crat es (MIL-C-52950).




6-8

Figur e 6-3. Styles of open crat es (MIL-C-52950).




6-9

Figur e 6-4. Assembly of open n ailed crat e (MIL-C-3774).

L a r g e O p e n C r a t e s

For milita ry use, there a re two kinds.

N a i le d C r a t e s

These crat es are designed for a net weight ran ging up to 12,000 poun ds. The

maximum size limit is n ot to exceed 16 feet in length , 8 feet in width, an d 8

feet in height (fig 6-4).

B o lt e d C r a t e s

These crates are designed for reuse with net weight ranging up to 16,000

pounds. These crates ar e designed with a size limit not to exceed 40 feet in

length , 8 feet in widt h, a nd 16 feet in h eight (fig 6-5).

S h e a t h e d c r a t e sA sheathed crate is similar to an open crate except that the frame members

are completely covered with sheat hing m ater ial, such as lum ber or plywood,

fasten ed to the frame. This adds strength to the cra te, prevents loss of

contents, r educes pilfera ge, and pr events th e direct entr y of dirt , water , etc.

The main difference between a nailed wood box and a sheathed crate is that

the top, bottom, and side faceboards of a nailed wood box provides the main

structural strength, whereas in a crate, the frame members susta in the load

and provide th e strength, Many sheat hed cra te designs exist in our military

system; however, the designs selected for this section are considered to be the

most widely an d gener ally used (fig 6-6).




6-10

Figur e 6-5. Assembly of open bolted cra te (MIL-C-3774).

S h e a t h e d N a i le d C r a t e s

These crates are not designed for reuse and are constructed in the same

man ner a s bolted crat es with m inor exceptions. The crates should not exceed

30 feet in length, 9 feet in width, and 10 feet in height. The net weight of

contents m ay ra nge up t o 30,000 poun ds. These limitat ions ma y be exceeded,

however, when t he size and weight of the item require a larger crate.

S h e a t h e d B o lt e d C r a t e s

All bolted cra tes ar e designed for reu se. The size an d weight limitat ions a re

the sa me as for th e nailed crat es.

Spec i a l Us e Cr a t e s

Cra tes in th is classification ar e of special design for specific items. These

crates may be fabricated of metal or wood, either open, sheathed, nailed, or

bolted. Crat e dimensions and weight will vary depending upon the size,

weight, an d chara cteristics of the conten ts. Exam ples of special cra tes ar e

illust ra ted in figure 6-7. The slott ed angle cra te (ASTM D6255) is an

example of special meta l crat e which ma y be either open (Type I) or shea thed

(Type II with eith er plywood, paper -overlaid veneer , or fiberboard . It ma y be

fabricated without skids (Style A), or with skid blocks or skids with rubbing




6-11

strips (Style B). Both t he open and sh eath ed Style A slotted a ngle cra tes ar e

restricted to items not to exceed 200 pounds, with dimensions not to exceed

80 inches in length , 30 inches in width, an d 48 inches in height, except wh en

a specific design has been approved by the contracting activity. Both the open

and th e sheat hed St yle B carr y up to 3,000 poun ds an d ar e limited to not over

30 feet in length , 4 feet in width , and 7 feet in h eight.

Figure 6-6. Sheath ed cra tes.




6-12

Figure 6-7. Special use crates.

Cr i t e r i a fo r Cr a t e Des i gn Crat es ar e selected inst ead of boxes for several rea sons. The item m ay be t oo

large to be shipped in a box. The weight of the item may exceed th e weight

limitat ions of a box specificat ion. The item may not requir e complete

enclosure for protection, yet it may require crating to facilitate storage and

ha nd ling. Cra tes provide bett er facilities for clear an ces, blocking, bra cing,

and a nchoring of th e item. To select th e proper crate for th e item or items to

be packed, it is necessary to consider certa in basic factors th at ma y influence

the selection.




6-13

Si ze an d Wei gh t

Basically, it is desirable to design a crate not to exceed 30 feet in length, 9

feet in width, and 10 feet in height, with a weight limitation not to exceed

11,200 pounds. This maximum size and weight is indicated becau se the

length of 30 feet will permit lowering the crate through the average ship's

ha tch without excessive tilting. The 9-foot width a nd 10-foot height is

designed for the average width and clearance limits for transporting by railon a standa rd flat car. Taking the weight factor into considera tion will

permit ease of han dling by t he average sh ip's h oisting facilities.

Degr ee o f Dis a s s em b l y

When determining the size, weight, shape, and strength, considerations

should be given t o partial disassembly of the item or its components to redu ce

the overall size of the cra te. However, do not disassemble the item to th e

point where special tools or p ersonnel ar e needed t o reassemble it.

Wei gh t Di s t r i bu t i on

In designing crates over 5 feet in length, weight distribution becomes an

import ant factor. Whenever possible, the center of gravity of the conten tsshould coincide with the geometrical center (center of balance) of the loaded

crate.

An c h o r i n g o f t h e C o n t e n t s

A thorough study of the contents should be made in order to insure that

provisions are made for anchoring the contents within the crate to prevent

dama ge dur ing ha ndling an d shipment. When necessary, use cushioning and

padding at point s on the item wher e blocking, bracing, or stra pping is used t o

prevent movement . Bolts, steel stra pping, iron bands, rods an d lumber

holddowns ar e acceptable meth ods for anchoring an d supporting t he conten ts

(fig 6-8). Some items a re designed with pa cking an d shipping in mind an d

are provided with holddown featu res. If the item does not ha ve these

cha racteristics, ut ilize th e str onger ar eas of the item for a nchoring.

C l e a r a n c e

Normally, a minimu m of one-inch clear ance is required between th e conten ts

and t he near est fra ming member of the sides, ends, and top. This clearan ce

allows for the distortion and vibration to which the crate may be subjected

during rough han dling and tra nsit . I tems that a re fragile in na ture, or items

within floating bag barriers (submethods 53 and 43) require from 2 to 4

inches of clear an ce. Additiona l clear an ce ma y be required for shock moun ted

items. Thr ough car eful design, it is often possible to allow protru ding points

of the item to extend between the joists, or the joists may be spaced, within

specified limits, to accommodate these protrusions.

Types o f Bas e s

The selection of a skid or a sill base will depend on the physical

cha racteristics of the item to be cra ted.

Si l l Base s

Sill bases (fig 6-9) are designed for items that can be supported above their

lowest point. Exam ples are tran smission housing engines and vehicles with

brake d ru ms pr ojecting below th e frame or a xles.




6-14

Figure 6-8. Methods of anchoring conten ts in crat es.




6-15

Figur e 6-9. Sill base.

S k i d B a s e s

Skid bases ar e designed t o accommodate loads t ha t can be su pported on th eir

lowest portion, or items th at a re ma de to rest flat on th eir bases. Skid-type

bases are pr eferred in m ost cases; however, when t he item m ust be supportedabove its lowest point, the use of a sill base will reduce the overall height of

the crate. Savings in height should be more th an 6 inches before substituting

a sill base for a skid ba se (fig 6-10).

E n g i n e e r i n g F a c t o r s i n C r a t e D e s ig n

A crate is an en gineered cont ainer. The use of soun d engineering principles

and actual tests of crates with contents has resulted in the following design

requirements.




6-16

Figure 6-10. Skid base.

Tops

The top of a sheathed crate is designed to carry a uniform, well-distributed,

superimposed load of 50 poun ds per squ ar e foot. Top loading plus t he spa n or

width of the crate will determine the kind of top an d th e size of joist required

to tran sfer th e load t o the sides.

S id e s a n d E n d s For crate design, the side and en d pan els of sheathed crat es are considered as

tru sses. The selection and size of members for th e sides and ends are

calculated on the bases of the span, height, and the amount of stress each

member can withsta nd. These cra te design factors are for sides having top

loads, with dunnage, in the amount of 200 pounds per square foot, for net

loads t o 10,000 poun ds. In a ddition, th ey may be designed for 400 pounds per

squa re foot, for n et loads over 10,000 poun ds.




6-17

B a s e s

The base is treated as a unit and is designed to support the contents. In the

engineering an alysis, the skids of the base ar e considered as par t of the lower

fra me members of th e sides. The lower frame members an d skids act

together when th e cra te is lifted as a unit. This ana lysis allows the redu ction

of skid sizes, thereby saving materials and cube, but does not allow the

han dling of a loaded crate without t he sides and ends in place. Skid sizesshould be increased if it becomes necessary to raise or move the loaded crate

without th e sides and en ds in place.

L o a d F a c t or s a n d H a n d l in g a n d S t o r a g e H a z a r d s

In a ddition to the externa l forces of superimposed loads an d t hose imposed by

the weight of the contents, crates are subjected to other hazards during

han dling and shipping. Crat es are designed to be han dled by forklift tr ucks,

slings, an d grabh ooks (fig 6-11). In order to prevent cru shin g, th e gra bhook

area s should be reinforced with additional mater ial. For hand ling with

forklift t ru cks, provisions a re ma de to enter from t he sides an d ends without

dama ging the floorboards a nd conten ts. Forklift ent ry from th e ends places

stress on the headers, load bearing floorboards, and forklift members.

Therefore, these members should be well secured with nails or bolts (fig 6-9an d 6-10).

M odes o f T r a ns p o r t a t i on

Crat es may be shipped by rail, truck, plane, or ship. Some of th e hazar ds

involved in shipment are shock stresses and impact stresses resulting from

sudden stops and sta rts. Vibrat ion is also a shipping hazar d. Crat es shipped

on open cars shall always be fastened secur ely to prevent an y movement. In

closed cars, there are several preferred methods of loading, some of which

allow movement u nder cont rolled conditions. The preferred meth ods are the

snubbed load, the floating load, and the rigid braced load. The method

selected depen ds upon t he fragility, size an d sha pe of the item, and the center

of gravity of th e loaded crate. The snu bbed load utilizes ant iskid plates,

while the floating load depends entirely upon the friction between the crate

and the car floor. These loads a re designed for items with a low center of

gravity. The rigid braced loads utilize lumber and metal stra ps. This

material should be applied in such a manner as to eliminate all movement.

Shiploading involves sta cking load str esses. Dun na ge should be placed on

top of crates, which h ave been designed t o carr y such loads.

E x p o s u r e a n d S t o r a g e

Sheathed crates will provide for long-term protection in exposed storage

conditions. Open cra tes are designed for items tha t require very little

protection from the element s. Sites selected for outside storage should be

well drained in order to prevent water and moisture form entering the crate.

Well constructed tops, proper drainage, and ventilation should preventdama ge to the cont ents when stored under adverse conditions. Stacking

stresses of superimposed loads ar e of major importa nce in storage. Open

crates are designed to withstand superimposed loads in storage with

additiona l dunn age placed on the top, tra nsferring the load to the sides.




6-18

Figur e 6-11. Resista nce to forces.

CRATE MATER IALS

LUMBER

Lumber used in crate construction must meet the same rigid requirements as

for oth er wooden cont ainers. Lumber u sed in cra te constr uction sh all be free

of defects th at would mat erially weaken t he conta iner. Knots an d divergence

of grain (cross-grain) are probably the most common defects in lumber used

for framing members, and will affect the strength of these members more

tha n the sheat hing boar ds. Knots or knot clusters th at exceed one-fourth t he




6-19

width of a structural member or that exceed one-third the width of a

sheat hing boar d, are prohibited.

Moisture content of lumber is an important factor and shall be not less than

12 percent nor more tha n 19 percent of its oven dry weight. Other wise,

shrink age may occur an d na il holding power ma y be reduced.

Divergence of grain (cross-grain) more than 1 inch in 10 inches in the length

of a p iece is pr ohibited.

The width and thickness of lumber used in fabricating crates are always

minimum from a design sta ndpoint. When nominal sizes are given in a crate

specification, the actual minimum sizes will be as indicated in table 6-1.

Note. All lumber dimensions referenced in th is section are nominal. Actua l

dimensions a re so indicated when actual sizes are required.

Table 6-1. Minimum Th ickness a nd Width of Lum ber

Thickness in inches

(smaller dimension)

Width in inches

(larger dimensions)

Nomina l size Minimum (actua l) Nominal size Minimum (actual)

1 3/4 2 1-1/2

3 2-1/2

2 1-1/2 4 3-1/2

3 2-1/2 5 4-1/2

4 3-1/2 6 5-1/2

5 4-1/2 8 7-1/2

6 5-1/2 10 9-1/2

7 6-1/2 12 11-1/2

P lyw ood (A-A-55057)

Plywood is used in crate construction for sheathing, for nonload bearing

flooring, for tops, an d gusset plates. While plywood is usu ally more

expensive than lumber, it required no diagonals or crate liner material when

used as sheathing, and a lighter, more economical crate may result from its

use. Tests have shown that plywood is actually stronger tha n lumber, the

dimensions being the same. When using plywood, select th e stan dar d size

sheet st ock t ha t conforms closest t o the cra te dimen sions, otherwise wast e of

ma ter ial will result. The typ e of plywood selected will be on th e basis of its

intended u se. Where prolonged exposur e to the elements or att ack by micro-organisms (mold, fungi, etc.) is expected, materials, must be selected that will

withsta nd th e extreme conditions.

Na ils (ASTM F 1667-95)

Nails are u sed in th e fabrication of the componen ts for both na iled an d bolted

cra tes. They are also used in the assembly of na iled crat es. The preferred

types of na ils used for crat e assembly are th e sinker, corker , or common. If

these nails are not available, coolers or standard box nails may be used.

Nails used for fastening plywood should be 14-gage with heads no less th an

7/32-inch diameter.




6-20

Sta ples (ASTM F 1667-95)

Staples are sometimes used to fasten plywood sheathing to the framing

members. When used for th is purpose, staples should be made of 16-gage

wire with a crown not less tha n one-half inch.

Bol t s , Nu t s , an d Was he r s Many types of bolts are used in crate construction. The most common types

used ar e stan dar d steel carr iage, step, and m achine bolts (fig 6-12). Bolt

holes should be drilled the sam e size as the sha nk of th e bolt. Plain wash ers

should be used under the heads of the machine bolts and under all nuts.

Special holding plates have been designed for use under the heads of square

shan k bolts to prevent tu rn ing. The use of plates is not man dat ory. Coun ter-

sinking of bolt h eads is prohibited. The bolt th reads pr ojecting beyond t he

nut after tightening should be painted with hard drying preservative,

un thinn ed paint or oth er similar m ater ial to prevent loosening.

Lag Bo l t s

Lag bolts are sometimes referred to as "lag screws". There a re th ree types of

lag bolts, Gimlet Point ; Cone Point ; an d Cone Point, Fet ter Dr ive (fig 6-12).There ar e two different t ypes of heads, Hex head a nd Squa re head . Lag bolts

are u sed to assemble the sides, ends, an t ops of demount able cra tes. These

bolts are prohibited for use as holddowns or to tie the headers and the

floorboar ds to th e skids. When u sing lag bolts for assem bly, drill the lead

hole to the same diameter as the sh ank, although the th readed portion m ay

be lar ger than the sha nk. The size of th e lead hole for th e thr eaded portion

will depen d upon th e group of wood used. When u sing lag bolts in soft woods,

mak e smaller lead holes. Use plain washers under th e heads and tighten

firmly against the washer (table 6-2).

Note. Lag bolts should never be driven with a ha mmer . When power wrench

is used, care must be taken t ha t th e bolts are not overdr iven.

Nut S leeve As s em bl y

A nut sleeve assembly, as illustrated in figure 6-13, may be used as an

altern at e for lag bolts in demount able crat es. These bolts must be the sam e

size as the fasteners th ey replace and are spaced the same distan ce apa rt.

Meta l S t ra pp ing (ASTM D 3953 and ASTM D 4169)

Metal strapping is used for reinforcing crate corners, sill bases, securing tops,

as lag bolts reinforcing straps for demountable crates, and for strengthening

sill an d load bear ing head ers for sill-type bases. It is also used t o rein force

cra te corn ers an d the tops of open crates. Metal stra ps used for this purpose

sha ll be Class 1 Type I or II, a nd not less t ha n 3/4 x 0.028-inch (fig 6-14).




6-21

Figur e 6-12. Bolts, screws, an d a ccessories.

Table 6-2. Applicat ion of Lag bolts

Diameter of

threaded portion of

lag bolts

Diameter of lead hole

Groups I, II an d

III wood

Group IV

wood

Inch Inch Inch

1/4.................. 3/16 3/16

5/16................ 1/4 1/4

3/8.................. 1/4 5/16

1/2.................. 3/8 7/16

5/8.................. 3/8 1/2

3/4.................. 1/2 5/8




6-22

Figure 6-13. Nut sleeve assem bly.

Figure 6-14. Tension a nd corn er str apping.




6-23

C o r n e r S t r a p s

Metal strapping used for reinforcing tops, corners, and sill-type bases is

usua lly annea led an d predrilled for ease of application. This type of

stra pping is used on a ll nailed crates a nd on bolted crat es with n et loads over

3,000 poun ds. The legs of the corner str aps ar e usua lly 8 inches in length .

They are nailed to the frame members with a minimum of three galvanized

roofing na ils, 1 1/4 to 1 1/2 inches long. The st ra ps ar e spaced no more tha n36 inches apar t.

T e n s i on S t r a p s

Tensions st rap s are u sed to secure t he top to the sides of the cra te by anchor

plates, which ar e nailed to the frame members. The straps ar e drawn tight

with a ten sioning device an d held in tension with two seals. Tensions str aps

are spaced no more tha n 6 feet apar t.

Lag Bo lt Re i n f o r c i ng S t r ap s

This stra p is fabricated from galvanized steel and is u sed on the side an d end

panels of many demountable crates to prevent the lag screws from tearing

thr ough th e sheat hing as the cra te is lifted. The strapping material is

prep un ched or pred rilled. Lag bolts 3/8 inch in length r equire 1 1/4 X 0.035inch str aps. For 1/2 inch a nd 5/8 inch lag screws, 2 X 0.050 inch st rap s are

needed. Nail these stra ps to the lower inner face of the sh eath ing between

the lower edge of the bottom fra me mem ber an d th e bottom of th e sheat hing.

Locate them to coincide with the center of the skids and headers. Use clout

or similar nails to secur e the stra pping. Space the nails a maximum of 2

inches on center and clinch at least three-fourths of an inch (fig 6-15).

M e t a l H a n g e r

Metal hangers are used for reinforcing joists of tops, load bearing headers,

and int ermediate sills on sill-type bases. Han gers are fabricated from steel

stra ps 1 1/4 X 0.035-inch. The strapp ing material is prepun ched or

predrilled. When used t o reinforce load bearing header s or intermediat e sills,

eightpenny nails are used to secure straps in place, followed by driving from

two to four twen typenn y nails into th e end-grain of the h olding member (fig

6-16).




6-24

Figure 6-15. Lag bolt reinforcing strap.




6-25

Figure 6-16. Use of meta l han gers.




6-26

Si ll Bas e S t r ap s

In ad dition t o the stra ps applied to other area s of th e crat e, sill bases must be

reinforced with 3/4 X 0.028-inch met al str aps (fig 6-17). Use a m inimu m of

three galvanized roofing nails 1 1/4 to 1 1/2-inch long in each leg of the strap.

Locat e all na ils to penetra te a framing mem ber.

Wat e r p r oo f L i ne r s an d Sh r oud s (P P P -B-1055) This waterproof barrier material is made by laminating layers of kraft paper

with asph alt. Seven different classes of mat erials may be used for cra te

liners. The most common classes used are E-1, E-2, and C-2. This mater ial,

when used as a liner, is placed horizontally between the sheathing and the

fra me members of the sides and ends. If more tha n one width of material is

required, use a minimum of 4-inch shingle lap for proper dra inage. The

bar rier should cover the ent ire fra med ar ea (fig 6-18) an d 6-19). When

vertical joints are required, the 4 inch lap will be located at a vertical

member. Liners ar e not required for plywood sheat hed cra tes. Inter ior

shrouds, lar ge bags, or en velopes fabricated from water proof barrier mat erial

are used in open crates to cover items which require additional protection.

All sharp projections of the item should be cushioned or padded to prevent

pun cturing the ma terial. The class of mat erial to use is optiona l, althoughthe most common class is E-2. All joint s in the ma terial are m ade by using

MMM-A-260 adh esive. Shr ouds should han g free of th e item t o provide

proper ventilation and should extend to within 6 inches of the bottom of

crat e. Mat erial conforming to Specification L-P-378 may also be used for

interior shrouds. This mat erial is constructed of polyethylene and does not

cont ain asp ha lt (fig 6-18 an d 6-19).

Roof ing Fe l t

Roofing felt is used in th e constr uction of tops for sheat hed crat es. This

material should have a smooth uncoated surface with a minimum weight of

45 poun ds per squa re (a squar e is an a rea of 10 feet by 10 feet, or 100 squar e

feet). The mater ial is placed between th e out er lumber sheat hing and inner

plywood shea th ing of th e top as illust ra ted in figur e 6-60. When a joint is

required, overlap the felt 4 inches and seal with a non-hardening caulk or

mast ic compoun d. As an a lterna tive, polyethylene film, not less tha n 4 mils

th ick, ma y be u sed in place of roofing felt.




6-27

Figur e 6-17. Applicat ion of str app ing (sill base).




6-28

Figure 6-18. Crat e liner.

Figure 6-19. Inter ior sh roud.




6-29

S c r e e n s a n d V e n t i la t o r s

Screens are fabricated from heavy rust-resisting wire of 1/4 or 3/8 inch mesh

and used over ventilating and drainage holes to prevent entry of birds,

insects, rodent s, or other a nimals. Ventilators fabricated from metal are

sometimes u sed over ventilating holes. Some of the most common m ethods

are illustra ted in figure 6-49.

I n s p e c t i on D o o r s

When inspection doors are required, they are made without cutting into the

fra ming members. Doors ar e fabricat ed form the same material as the

sheat hing. Hinge at th e top and fasten with lag bolts or wood screws at th e

sides and bottom (fig 6-20). Make cleat s and st ops from 1-inch ma ter ial.

Drill holes th rough th e door a nd a djacent fra me mem ber to pr ovide for a sea l

wire and lead seal bearing the inspector's stamp . The size an d location of th e

doors will vary with t he n atu re of the item .

Fi gu r e 6 -20. Cr a t e i n s pec t i on doo r .




6-30

WOOD CRATES , OP EN AND COVER ED , MIL-C-52950 (GE NER AL)

C RATE DESIGN

Open wood crates described in this section are designed for general use and

are em ployed for both domestic an d oversea sh ipments. Only items wh ichare not readily damaged from outside forces and which require limited

protection should be shipped in open crates. Usua lly, items which ar e

designed for outdoor use or of ru gged constru ction ar e shipped in open crates.

When t here are a var iety of items to be shipped, each crate will be designed

for each item with the necessary clearance for blocking, bracing, and

cushioning (fig 6-21).

Figure 6-21. Use of table to determine thickness of load

bearing floorboards.




6-31


Crates fabricated or procured under MIL-C-52950 on the basis of weight, size,

and constr uction featu res, as indicated in t able 6-3.

Wo o d R e q u i r e m e n t s

The divergence of grain (cross-grain) should not exceed one inch in ten inches

of length . Plywood, wh en u sed, will conform to A-A-55057.

Nai l s an d Na i l i ng

Nails used shall be sinkers, coolers, corkers, or common. For fastening

covering materials to members, nails shall be not less than 1 inch long but

shall not exceed the sum of the thickness of the covering material and

mem ber. Na ils sizes specified for the fabr icat ion of th e various cra tes ar e

based on Groups I a nd II woods.

When group III or IV woods are used, nail sizes may be onepenny size

smaller tha n th ose specified. The pat tern s to be used for th e nailing of two

flat pieces of lumber shall conform to the details shown in figure 6-22. Unless

otherwise specified herein, the following requirements shall determine size,

placement , and qu an tity of na ils.

• All adjacent crate members shall be securely fastened to each other,

either directly or by means of the covering.

• All nails that are not to be clinched shall be cement coated or

mechanically deformed (spiral or roun d t hrea ded).

• Nails shall be driven through thinner member into the thicker

member wherever possible.

• When the flat faces of pieces of lumber are nailed together and the

combined thickness is 3 inches or less (except for top joints and

covering material), nails shall be long enough to pass through both

thicknesses and sha ll be clinched not less tha n 1/4 inch nor more t han

3/8 inch.

• When the flat faces of lumber are nailed together and the combined

thickness is more than 3 inches or when the flat face of one or more

pieces is nailed to the edge or end face of another, nails shall not be

clinched. The portion of th e nail in the th icker piece shall not be less

than 2 times the length of the nail in the thinner pieces for tenpenny

nails and smaller, and not less than 1 1/2 inches for twelvepenny

nails and larger.

ο When splitting occurs with the use of diamond point nails, the

nails shall be slight ly blunted. When blunting does not prevent

the splitting, holes slightly smaller than the diameter of the nail

sha ll be drilled for ea ch na il.

οNails shall be driven so that neither the head nor the pointprojects above th e surface of th e wood. Occasiona l overdr iving

will be permitted, but nails shall not be over-driven more than

one-eighth the th ickness of the piece holding th e hea d.




6-32

Figure 6-22. Nailing pat tern s. (All widths nominal). Similar pa tter ns

shall be used when boards cross at a ngles other tha n 900.

Table 6-3. Classification of MIL-C-52950 Crat es

Style A - Heavy Duty Style B - Light Duty

Type Maximum

net load

Maximum In side Dimensions

Maximum

net load

Maximum In side Dimen sions

Length Width Height Length Width Height

(pounds) (feet) (feet) (feet) (pounds) (feet) (feet) (feet)

I 250 4 3 3 200 4 3 3

II 1 1000 12 4 2 NO STYLE B

III NO STYLE A No load or size r est r ict ion except as limited by

handling methods.

IV 1000 6 4 4 NO STYLE B

V2 2500 12 6 6 4000 32 6 10

1Items such as ladders, tubing, and extrusions weighing less than 200 pounds and not exceeding 20 feet long, 3 feet

wide, and 2 feet high may be pa cked in Type II crat es.2Type V, Styles A and B crates shall be further classified as being nondemountable or demountable. Type V, Style B

crates ma y be open or covered.




6-33

ο Nails shall be positioned not less than the thickness of the piece

from th e side end nor less th an one-ha lf the th ickness of the piece

from the edge of the lum ber whenever possible. Nails driven into

the side edge of the lumber sh all be center ed on the side edge.

ο When two members having parallel grain are attached, the

nu mber of rows of nails shall be determined by th e nominal widthof th e sur faces in conta ct, one r ow for widths u p to a nd including

2 inches, two rows for widths greater than 2 inches but not

greater tha n 6 inches, and th ree rows for widths over 6 inches.

ο When plywood is nailed to cleats, nails shall be spaced not more

tha n 4 inches apart on center s placed in staggered rows which a re

less than 1 3/4 inches ap art or less than 3/4 inches from th e edge

of th e cleat .

St ap l e s

The crown of the staples used for fastening covering materials for frame

members sha ll be not less than 3/8 inch. The length of the st aples shall not

exceed the sum of the thicknesses of the covering materials and the frame

member; however, staples sha ll be not less tha n 1 inch in length .

Bolt app l ica t i on

Holes shall be prebored to receive carriage bolts and shall be the exact

diameter of the bolt. The lead holes for lag bolts shall be the sa me diamet er

as the sha nk, even th ough th e threaded portion ma y have a greater diameter

than the shank.

Spl ices

Splices an d but t joints m ade in fram e members a nd skids of long crat es sha ll

be as sh own in figur e 6-23.




6-34

Figu re 6-23. Splicing of mem ber s: A, splice of 4 x 4 inch or 4 X 6 inch sk ids; B, splice of 2 inch

mem ber; C, splice of 1 inch m ember ; D, lam ina tion of skid.

TYPE I, STYLE A - HE AVY DUT Y CR ATE (MIL -C-52950)

DESIGN R EQUIREMENTS

L o a d a n d S iz e L im i t a t i o n s

Limitat ions sh all be as specified in ta ble 6-3.

Style A crates shall be used only for items forming a Type I load and

weighing not more tha n 250 poun ds.

B a s e

S k i d s

The skids sha ll be 2 by 4 inch lum ber.




6-35

Diagonals

Diagonals sh all be 1 by 4 inches in size.

En d Floor Members

En d floor members sha ll be the sam e thickness an d width as t he skids except

when used a s loadbear ing members; their size sha ll be as specified in ta ble 6-

4. En d floor members sha ll be bolted to each skid with 3/8-inch diamet ercarriage bolts.

R u b b i n g St r i p s

Single piece rubbing strips used on each skid shall be a minimum 3 by 4

inches in size and beveled at each end at an angle of 45 degrees for at least

one-half their th ickness. The length sh all be less than t he skid length to

allow open space at each end for sling and fork lift han dling. The open space

shall be not less th an 4 inches and not more tha n 10 inches long. On crates

over 36 inches long, the rubbing strip length shall be adjusted to provide a

distance of not more th an 28 inches between end openings.

S i d e , E n d a n d T o p P a n e ls

All members of the side, end and top panels shall be 1 by 4 inch lumber.Nailing patt erns sha ll be as specified in figur e 6-22.

ASSEMBLY

Assembly of the crates shall be as shown in figure 6-24 and as specified

herein. The sides shall be fasten ed to the base by nailing the extensions of

the vertical struts an d diagonals to the skids with eightpenn y na ils. The

ends shall be fastened to the base by nailing the lower edge member of the

panels to the end floor member with eightpenny nails spaced 6 to 8 inches

apar t. The sides sha ll be fasten ed to th e ends by nailing the end vertical

struts of the sides to the vertical struts of the ends with eightpenny nails

spaced 8 to 10 inches apa rt. The sides shall be fasten ed to the top nailing the

extensions of the diagona ls and vert ical stru ts of the sides to the longitud inal

members of the top with eigthp enny na ils. The top shall be fasten ed to the

ends by nailing the extensions of the longitudinal and diagonal members of

the top to the upper edge member of the ends with eightpenny sinker nails.

The upper edge members of the ends shall be nailed to the edge lateral

members of the top with eightpen ny sinker n ails spaced 8 to 10 inches apar t.

TYPE I, STYLE B--LIG H T DU TY CRATE (MIL-C-52950)




Style B crat es sha ll be used only for items forming a type I load an d weighing

not more than 200 pounds.

F r a m e M e m b e r S i ze

All frame members shall be 1 by 3 inches in size for net loads up to 100

pound s by 1 by 4 inches in size for loads bet ween 100 t o 200 pound s.




6-36

Figur e 6-24. Type I, st yle A cra te a ssembly (MIL-C-52950).

Assembly

Assembly of the crat es shall be as shown in figur e 6-25. Diagona ls, struts,

cross members, and longitudinal members shall be nailed together in

patt erns a s shown in figure 6-22 with sixpenny na ils.




6-37

Figur e 6-25. Type I, st yle B crat e as sembly (MIL-C-52950).

TYPE II, ST YLE A--H EAVY DUT Y CRATE (MIL-C-52950)




E n d s

The end s sha ll be of lum ber or cleat ed-plywood as shown in figur e 6-26. Thecleats sh all be fasten ed to th e end board s or to th e plywood with two r ows of

nails spaced 4 inches apa rt in each row, staggered and clinched. The

minimum thickness of the end boards and plywood and the size of the end

cleat s sha ll be as shown in t able 6-5. Additiona l vertical filler cleats sh all be

used in the ends when the unsupported span between outside cleats is

greater tha n 3 feet.

Si des

The sides of the crates shall be of lumber or cleated-plywood as shown in

figur e 6-26.




6-38

Figur e 6-26. Type II, st yle A cra te a ssembly (MIL-C-52950).

Table 6-4. Allowable Load P er Inch of Load-bear ing Floorboar d Widthof Groups I an d II Woods

Distance

between

skids

Nominal Th ickness of Floorboards (inches)

1 2 3 4 6 8

12 50 200 557 1090 2690 4680

18 34 134 370 740 1790 3140

24 25 100 280 545 1350 2330

30 20 80 222 450 1150 1870

36 17 66 185 361 895 1560

42 15 57 158 311 767 1335

48 12 50 139 272 671 117054 11 45 124 242 596 1039

60 10 40 111 218 537 936

66 9 37 104 198 488 850

NOTE: When Group IV woods are us ed, the above allowable loads

ma y be increased by 20 percent.




6-39

Table 6-5. Thickne ss of En ds

Maximum

Net Load

Plywood Lumber Size of end

cleats

(pounds) (inch) (inches) (inches)

100 ¼ 3/4 3/4 by 2-3/4

250 3/8 3/4 3/4 by 3-1/2500 ½ 1-1/6 1-1/16 by 3-1/2

1000 ½ 1-5/16 1-1/2 by 3-1/2

Table 6-6. Thickne ss of Sides

Maximum

Net Load

Plywood Lumber Size of Clea ts for

Plywood Sides

(pounds) (inch ) (inches) (inches)

100 1/4 3/4 3/4 by 2-3/4

250 3/8 3/4 3/4 by 2-3/4

500 1/2 1-1/16 7/8 by 3-1/2

1000 1/2 1-5/16 7/8 by 3-1/2

When lumber is used, the sides sha ll be constr ucted of not more t han 3 pieces

for heights of 1 foot 3 inches or more, not more than 2 pieces for heights

between 7 1/2 inches and 1 foot 3 inches, and one piece for heights 7 1/2

inches or less.

The minimum thickness of lumber and plywood, and the minimum size of

cleat s for plywood sides sh all be as sh own in ta ble 6-6.

When lumber sides are composed of two or more pieces, cleats that are the

same thickness and width as the top and bottom crossmembers shall extend

the full depth of the side and shall be fastened to the inside surfaces of the

sides as shown in figure 6-26. The cleat s on th e sides sha ll be placed to

coincide with the crossmembers of the top, and spacing shall be no greater

than 3 feet. Cleats shall be fastened to the side boards or plywood with two

rows of nails spaced 4 inches apart in each row, staggered, and clinched.

When the overall length of the crate exceeds 14 feet, pieces of lumber used in

the construction of the sides shall be either the required full length or shall

be made u p of two pieces which t ogether ma ke up t he full length. The joint of

such pieces sha ll abut on a full depth cleat, an d both pieces sha ll be na iled to

the bottom.

When plywood is used, the sides shall be constructed on one-piece material

for width r equirement s. Butt jointing of plywood at a n inter mediate cleatlocation will be permitted when two lengths of plywood are required for

crat es in excess of 8 feet in length .

Crates may be one of the following combinations of sides and end panels, as

specified:

• Lumber ends and sides.

• Cleated-plywood ends and sides.

• Lumber ends an d cleat-plywood sides.




6-40

T o p a n d B o t t o m M e m b e r s

The top and bottom members shall be 1 X 4-inch lumber for all crates up to

an d including 2 feet 6 inches in width a nd 1 X 6 inch lumber for crat es more

tha n 2 feet 6 inches in width . The angle between diagona ls and side shall be

between 300 and 600, but crossmembers sha ll be placed not more th an 3 feet

apar t in line with ba tten s or cleats of the sides. The crossmembers of th e top

and bottom shall be directly opposite each other and the bottom diagonalsshall be in r everse direction with t he t op diagonals a s shown in figure 6-26.

Ext e r i o r S ide C l ea t s

When specified, for gross weights exceeding 200 pounds, exterior side cleats

sha ll be used to facilitat e fork lift han dling of crat es on th eir sides. On

lumber sides, the exterior cleats shall replace the int erior side batten s. On

plywood sides, filler pieces shall be used under the exterior side cleats; filler

pieces shall pass between the horizontal cleats and shall be the same width

as exter ior side cleats . Spa cing of cleat s sha ll be as shown in figur e 6-27.

Size of exter ior side cleat s sha ll be 3 X 4 inches. Ext erior side cleat s sha ll be

secur ed to the side sheath ing with n ails as specified for batten s. Short one-

pan el cra tes with lumber ends sha ll ha ve end cleats a n omina l 3 inches th ick

in lieu of exter ior side cleats .

ASSEMBLY

S i d e s t o E n d s

The sides shall be na iled with sinker or corker na ils to th e ends as specified

in ta ble 6-7.

T o p a n d B o t t om M e m b e r s t o S i d e s

The top an d bottom crossmembers an d diagonals shall be na iled to th e cleats

of the sides or to the lumber sides with eightpenn y sinker na ils when t he side

cleats or sides are less than 1 inch in thickness and ninepenny sinker nails

when side members are 1 inch or more in th ickness. The end top and bottom

crossmembers shall also be nailed to the end sheathing or cleats if the ends

ar e lum ber or plywood, respectively. The na iling pat ter ns, location of na ils,

and na iling procedur es sha ll be as shown in figures 6-22 and 6-26.

TYPE III , STYLE B--LIG H T DU TY CR ATE (MIL-C-52950)


Style B

Style B cra tes sh all be as shown in figure 6-28. Ther e sha ll be no size or load

restr ictions for th is cra te except as limited by ha ndling methods. The size

an d spacing of mem bers sh all be as specified in ta ble 6-8. Vertical end cleats

shall be long enough t o permit full na iling to the u pper h orizontal end cleatswhen t he crate is assembled.

Nai l i ng

The upper and lower halves of the crate shall be fabricated with sixpenny

nails; the vertical end cleats sh all be fastened t o the lower ha lf with clinched

nails to the lower horizont al end cleats. Two nails shall be used in each en d

of 3 an d 4 inch wide longitu dinal members a nd t hr ee nails shall be used in 6

inch wide longitudina l members.




6-41

Figur e 6-27. Type II, cra te with ext erior side cleat s. (A- complete crat e, B- two pan el, C- th ree

pan el, an d D- four pan el.


Beveled rubbing strips, of sizes shown in table 6-8, shall be attached to the

undersurface of each lower crossmember to facilitate fork truck handling.

Rubbing strips shall be fasten ed to the crossmembers with sixteenpenn y nails

placed in two rows and spaced 5 inches apart applied to each row and

clinched. Rubbing strips shall be applied at time of cra te packing after

stra pping has been secured to crossmembers.




6-42

Assembly

Assembly of th e cra tes sha ll be as shown in figure 6-28. After item s have

been nested in the lower half of the crate, the upper half shall be positioned

and str apping shall be applied. The upper ends of the vertical end cleats

shall be na iled to the u pper horizonta l end cleats with four penny na ils. The

upper longitudinal members of the sides shall be nailed to the vertical end

cleats with eightpen ny na ils.

Figur e 6-28. Type III , style B cra te a ssembly (MIL-C-52950).




6-43

Table 6-7. Na iling Schedu le for Assem bly to Type II, Style A Cra tes

Cleated-Plywood Sides

to Plywood or Lu mber E nds1

Lumber Sides to Lumber Ends 1

Plywood

thickness

Nail size Nail spacing Thickness of sides Nail size Nails spacing

1/4 8 3 3/4 8 2-1/2

3/8 10 3-1/4 1-1/16 10 2-3/41/2 12 3-1/2 1-5/16 12 3

NOTE: 1/ Nails shall be staggered when ends a re lumber.

TYPE IV, STYLE A - H EAVY DUT Y CRATE (MIL-C-52950)


L o a d a n d S i z e R e q u i r e m e n t s

The limita tions sh all be as specified in ta ble 6-3.

B a s e

Skids shall be 2 X 4 inch lumber for loads through 500 pounds and 2 X 6 inch

lumber for over 500 pounds.

The size of the load-bearing floor member shall be as specified in table 6-4.

Floorboards over 2 inches in nominal thickness shall be bolted to the skids

with 3/8-inch diam eter car riage bolts. Diagonals sh all be 1 X 6 inches.

The placement of end floor members and ru bbing str ips shall be as sh own in

figure 6-29. On crates over 5 feet long, the r ubbing strips sha ll be in th ree

pieces, with the center piece 16 inches long, the fork openings 12 inches long,

an d th e end p ieces of a lengt h wh ich will allow end s ling open ings of 4 inches.

S i d e , E n d , a n d T o p P a n e lsAll the members of the side, end and top panels shall be 1 X 6 inch lumber.

Three vertical struts shall be used in the side panels when the length of the

cra te is greater t ha n 4 feet or greater t ha n 1 1/2 times the height. The latera l

members of the top panel shall coincide with the vertical struts of the side

pan els an d shall be equal in number. Nailing patt erns sha ll be as shown in

figur e 6-22.

Assembly

Assembly of th e cra tes sha ll be as shown in figure 6-29. The longitu dina l

members of the top shall bear on the upper frame members of the sides and

the end lateral members of the top shall be adjacent to the upper member of

the ends.

TYP E V, STYLE A - H E AVY DU TY (MIL -C-52950)



The limita tions sh all be as specified in ta ble 6-3.

Nailing shall be as shown in figure 6-22.




6-44

Figur e 6-29. Type IV, style A cra te a ssembly (MIL-C-52950).




6-45

Figur e 6-30. Type V, style A cra te a ssembly (MIL-C-52950).




6-46

B a s e

S k i d s

The skids sh all consist of 4 X 4 inch lumber . An inter media te 4 X 4 inch skid

shall be used when the distance between the outer skids is greater than 36

inches.

L o a d -b e a r i n g F l o or M e m b e r s

The size of the load-bearing floor members shall be as specified in table 6-4.

Floorboards over 2 inches in nominal thickness shall be bolted to each outside

skid with 3/8 inch carriage bolts.

Di agona l s

The diagona ls shall be 1 X 6 inch lum ber an d th e an gle between th e skid an d

the diagonal shall be between 30 degrees and 60 degrees, except that when

the a ngle of a single diagonal is less tha n 30 degrees, two diagona ls and a 1 X

6 inch center crossmember sh all be used.

C r o s s m e m b e r s

End crossmembers shall be 2 X 6 inch lumber for crates not greater than 4feet in width and 4 X 4 inch lumber for crat es over 4 feet in width. En d

crossmembers shall be bolted to each skid with 3/8-inch diameter carriage

bolts.


Rubbing strips sh all be as described previously.

E n d s

Vertical stru ts sha ll be 2 X 4 inch lumber. An int ermediate str ut sh all be

used when the width of th e crat e is great er tha n 3 feet. All stru ts shall

coincide with the skids and shall bear upon the end crossmembers of the

base. The upper a nd lower frame mem bers of th e ends shall be 1 X 6 inch

lumber except the a 1 X 8 inch lower member shall be used when the end

crossmembers of the ba se are 4 X 4 inches. The diagonals of the ends sh all be

1- X 6-inch lu mber .

Si des

All side fra ming members, stru ts, and d iagonals sha ll be 1 X 6 inch lumber.

Intermediate struts shall be placed so that diagonals form an angle of

between 30 an d 60 degrees with the lower fram e member. Stru ts shall have

a ma ximu m spacing of 42 inches. A horizonta l int ermediat e fram e member is

required when th e height of the side exceeds 4 feet. Diagona ls shall be used

between each two adjacent stru ts.

Top All members of the top shall be 2 X 4 inch lum ber. The longitudin al members

shall coincide with the vertical strut s of the ends. An int ermediate

longitudina l member is required when t he width of th e cra te is greater t han 3

feet and sh all coincide with th e intermediat e stru ts of the en ds. The joists

shall be placed flat. J oists sha ll coincide with each stru t of th e side but sha ll

be spaced not more than 40 inches apart for crates up to 3 feet wide and not

more than 30 inches apar t for crates more tha n 3 feet wide. The diagona ls

shall be na iled to th e longitu dinal members. When more tha n th ree joists are

used, only each end panel of the top assembly shall be braced as shown in

figur e 6-30.




6-47

Non- dem oun t ab l e Cr a t e As s em bl y

The assem bly shall be reinforced by the application of metal str aps a s sh own

in figure 6-30.

Si des t o Bas e

The sides shall be fastened to the base by nailing the overlap of the verticalstru ts and diagonals to the skids with twelvepenny nails. The nailing

patterns shall follow those shown in figure 6-22.

E n d s t o Ba s e

The ends sh all be fasten ed to the ba se by nailing t he lower fram e member of

the en d pan els to th e end crossmembers of th e base with t welvepenny sinker

nails spaced 6 to 8 inches ap art .

S id e s t o E n d s a n d E n d s t o S id e s

The edge struts of the sides shall be fastened to the edge struts of the ends

with eightp enny sinker n ails spaced 8 to 10 inches apart . The extensions of

the upper and lower frame members and the diagonals of the end shall be

nailed to the edge stru ts of the side with eightpen ny sinker na ils as sh own infigur e 6-22.

T o p t o Si d e s a n d E n d s

The top shall be fastened to the sides and ends by nailing the upper frame

members of the ends and the extensions of the vertical struts and diagonals

of the sides to the adjacent edge members of the top with eightpenny sinker

nails as shown in figure 6-22.

D e m o u n t a b l e C r a t e As s e m b ly

All demoun table crates sha ll be assembled with lag bolts. Lead holes shall be

used for all lag bolts. When specified as an altern ate, th e top, side, an d end

panels may be nailed to each other and the unit may be fastened to the skids

and end crossmembers of the base by means of lag bolts for demountable

crates.

Si des t o Bas e

Lag bolts, 3/4 by 3 1/2 inches, shall be used to fasten the sides to the skids.

Diagonals shall be arranged to provide the maximum number of fastening

points to the base near t he center of the skids. The minimum nu mber of lag

bolts sh all correspon d to th e following tabu lation. Not less tha n one edge bolt

shall be placed in each stru t a nd diagonal.

Gross Load Minimum Number of 3/8-inch Lag bolts

(cra te and contents) for each side of cra te

(pounds)

1000 4

2000 5

3000 8

E n d s t o B a s e , s i d e s t o E n d s , a n d E n d s t o T o p

Lag bolts, 5/16 by 3 inches, spaced 12 to 14 inches apart, shall be used to

fasten : the lower edge members of th e ends to the end crossmembers of the

base; the end vertical struts of the sides to the edge struts of the ends; and

the u pper edge mem bers of the en d to th e edge joists of the top.




6-48

Si des t o Top

One 5/16 by 3-inch lag bolt sha ll be used to fasten each str ut an d diagonal of

the sides to th e edge longitudina l member of the top.

TYPE V, STYLE B --LIG H T DU TY CRATE (MIL -C-52950)


L o a d a n d s iz e L im i t a t i o n s

The limitat ions sh all be as specified in ta ble 6-3. They sha ll be open , or

covered, and demounta ble or n on-demount able as specified. Nailing shall be

as shown in figure 6-22, and as specified herein.

B a s e

S k i d s

Skid sizes sh all conform t o the following:

Skid Size (Nomina l)

Net load (pounds) 2 Skids (inches) 3 Skids (inches)

Up to 500 2 X 4 (fla t ) 2 X 4 (fla t )

501 to 2000 3 X 4 (flat ) 3 X 4 (fla t )

2001 to 3000 4 X 4 3 X 4 (flat )

3001 to 4000 4 X 4 4 X 4

Cr a t e s Ove r 42 I nch es Wi de Sha l l Have Th r ee Sk i ds

Splices sha ll be located no fur th er from the en ds th an one-th ird of the length

of th e skids, and splice locations sha ll be alter na ted in a djacent skids. All 4 X

4 members may also consist of two 2 X 4's placed on edge and laminated in

accorda nce with figur e 6-23.


Rubbing strips shall be a minimum of 3 X 4 inches in size. The str ips shall be

positioned a s shown in figure 6-31. They sha ll be na iled to the sk ids with two

rows of nails spaced 1 foot a part in each r ow in a st aggered pat tern ; nail sizes

shall be sixteenpenn y when skids a re 2 X 4 inches an d twen typenn y for 3 X 4

and 4 X 4 inch skids.

E n d H e a d e r s

Two headers spaced 2 feet apart shall be bolted to each end of the skids as

shown in figure 6-31 with 3/8-inch diameter carriage bolts. The end h eaders

shall be the same cross section a s th e skids. When crate en ds ha ve 2 X 4 inch

stru ts, bolts in the outer h eaders sh all be placed to clear th e stru ts.

L o a d -b e a r i n g F l o or b o a r d s

When concentrated loads occur, load-bearing floorboards shall be used to

tr an sfer the load to skids. The sizes sha ll be as specified in ta ble 6-4. When

end headers are used as load-bearing member, the end header size shall be

chosen from the load-bearing floorboard width specified in table 6-4.

Floorboards 2 inches or less in thickness shall be nailed to each skid in

patt erns as sh own in figur e 6-22 an d floorboards over 2 inches t hick shall be

bolted to each skid with 3/8-inch diam eter car riage bolts. Two bolts sh all be

used for floorboards over 6 in ches wide.




6-49

D i a g on a l s a n d F l oo r b o a r d s

Diagonals shall be used between headers and load-bearing floorboards or

other crossmembers a nd sh all be placed at a n a ngle as close to 45 degrees as

possible. Diagonals an d floorboar ds oth er th an load-bearin g floorboar ds sha ll

be 1- by 4-inch members for net loads up to 500 pounds and outside widths

not exceeding 3 feet, and shall be 1- by 6-inch members for all other

conditions.

Si des

Sides sha ll be as shown in figur es 6-32, 6-33, and 6-34 Single-panel sides

shall be used for heights over 6 feet. An intermediat e longitudina l member

sha ll be added for height s over 4 feet. Double-pan el sides sha ll be used for

heights over 6 feet and thr ough 8 feet. Triple-pan el sides shall be used for

height s over 8 feet. Longitud ina l mem bers sha ll be in single pieces for

lengths not exceeding 16 feet, and may be spliced as shown in figure 6-24 for

lengths greater tha n 16 feet. Splice locations shall be altern ated. Member

sizes and s pacing sh all be as specified in ta ble 6-9.

E n d s

En ds sha ll be as shown in figur es 6-35 and 6-36. All members sh all be 1 by 4inches in size for net loads up to 500 pounds, and 1 by 6 inches for net loads

over 500 pounds , with t he following exceptions.

Stru ts sh all be 2 by 4 inches in size when t he crat e height is over 5 feet.

The lower frame mem ber sha ll be 1 by 6 inches in size when th e end h eaders

of the base are 2-inch thick members and 1 by 8 inches in size when larger

end headers are used.

Top

The top shall be as shown in figur e 6-37. The spa cing of th e crossmem bers

shall be the same as th e spacing of th e side stru ts. Diagona ls shall be nailed

to the inner faces of the crossmembers. The longitudina l members sha ll be 1

by 4 inches in size for loads u p to 500 pounds a nd widths t o 4 feet, an d 1 by 6

inches for all other conditions Crossmembers and diagonals shall be 1 by 4

inches for loads t o 1,000 pound s an d width s to 4 feet, an d 1 by 6 inches for a ll

other cond itions. Splicing of longitu dina l mem bers sha ll be as shown in

figur e 6-23.

Top Re i n f o r c i ng J o i s t s

When the gross weight of the crate is over 500 pounds or the inside width is

over 3 feet 6 inches, a 2- by 4-inch top-reinforcing joist shall be nailed to the

top at the loaded center of balance as sh own in figure 6-37 to prevent t he t op

of the crate from being crushed when the crate is lifted with a single set of

grabhooks. The joist shall be placed flat an d th e ends sha ll conta ct th e innerface of the upper longitudinal members of the side when the crate is

assembled. The joist shall be fastened to the longitudinal and diagonal

members of the top with sevenpenn y nails placed as sh own in figure 6-22 and

to the upper longitudinal members of the sides with two tenpenny nails in

each end.




6-50

Figur e 6-31. Bases for Type V, style B cra tes (MIL-C-52950).




6-51

Figur e 6-32. Simple pa nel sides for Type V, style B cra tes (MIL-C-52950): A, side of long cra te;

B, side of short crat e; C, covered side.




6-52

Figur e 6-33. Double pa nel sides for Type V, style B crat es for h eights u p to 96 inches (MIL-C-

52950): A, open side ; B, covered side .




6-53

Figur e 6-34. Triple pa nel sides for Type V, style B cra tes for height s over 96 inches (MIL-C-

52950): A, open side; B, covered side.




6-54

Figur e 6-35. En ds for Type V, style B crat es (MIL-C-52950): A, two pa nel h orizont al; B, single

pan el covered; C, four pa nel; D, two panel vert ical.




6-55

Figur e 6-36. En ds for Type V, style B cra tes (MIL-C-52950): A, wide and n ar row double-pan el

ends; B, wide and n ar row triple-pan el ends.




6-56

Figur e 6-37. Tops for type V, style B cra tes (MIL-C-52950): A, na rr ow top; B, medium t op; C,

wide top.




6-57

Assembly

Unless demountability is specified, the crate shall be assembled by nailing.

When demountability is specified, the sides, ends, and top as a unit shall be

secur ed to the base with lag bolts. Eightpen ny na ils, spaced 8 to 10 inches

apar t, shall be used to fasten:

• th e edge strut s of th e sides to th e sides to the edge str ut s of the en ds;• the longitudinal members of the top to the upper frame members of the

sides;

• th e end crossmembers of th e top to the upper fra me mem bers of the ends;

and,

• th e lower frame m embers of th e ends to the en d hea der of th e base.

Eightpenny nails as shown in figure 6-22 nailing patterns shall be used to

fasten:

• the upper ends of the side struts and diagonals to the longitudinal

members of the top; an d

• the ends of upper and lower frame members, horizontal members, and

diagona ls of the ends to the edge str ut s of the sides.

The bottom ends of struts and diagonals of the sides shall be secured to the

skids with eightp enny n ails as follows: A minimu m of thr ee nails shall be

used for each 3 and 4 inch wide member, four nails for each 6 inch wide

member, an d five nails for each 8 inch an d wider member. Nails shall be

staggered and sha ll be placed in two rows whenever possible. For

demountable crates, each strut and diagonal of the sides shall be fastened to

the skids with a minimu m of one lag bolt. The size of lag bolts a nd t he total

nu mber required sha ll be not less th an t hat specified in ta ble 6-10. When

more than one lag bolt is required in each strut or diagonal, the additional

lag bolts sha ll be placed in th e wider members, n ear the load-bearing point s,

and in a staggered patter n when possible. One-half the total num ber of lag

bolts required sha ll be used for each side. For demounta ble cra tes, the lower

frame members of the ends shall be fastened to the end headers of the base

with 5/16 X 3 inch lag bolts, spa ced 12 inches a par t.

C o v er e d C r a t e s

The str uctur al framework of th e covered crates sha ll be as shown in figur e 6-

32 an d 6-33. The covered crat es shall also be as shown in figures 6-32

th rough 6-38. Un less other wise specified, th e covering shall consist of

plywood or paper-overlaid veneer with a minimum thickness of 1/8 inch.

When joints ar e required in t he covering they sh all butt over th e center line of

stru ts or crossmembers. Covering shall be fasten ed with two rows of nails or

staples, spaced 8 inches apar t in each row, staggered, and clinched. Filler

pieces between struts, diagonals, and crossmembers of sides, ends, and top

shall be fastened with two rows of nails, spaced 10 inches apar t in each row,staggered, and clinched. Filler pieces shall be the sam e thickness as a djacent

panel framing members.

Si des

Four-inch wide filler pieces shall be fastened to the upper and lower frame

members between the struts and diagonals. Filler shall extend beyond the

edge of the upper frame member so as to be flush with the ends of the struts

an d diagonals. The lower edges of th e fillers sh all be flush with t he bottom

edge of the lower frame m ember.




6-58

E n d s

Three-inch wide filler pieces shall be nailed to the edge struts as shown in

figur es 6-35 and 6-36. When sp ecified, end vent ilation sha ll be provided in

accordan ce with MIL-C-104.

Tops

Two-inch wide filler pieces shall be fastened to the longitudinal members.The covering of the top shall be extended to overlap the covering of the sides

and en ds. During na iling, a 4-inch wide strip of water proof barr ier mater ial

conforming to PPP-B-1055, class suitable for crate liners, shall be placed

un der each covering joint . The strip sha ll extend across the full width of the

top.

Cover ed Cr a t e As s em bl y

The assembly of covered Type V, style B crates shall be as shown in figure 6-

38. Ninepenn y nails, spaced 8 to 10 inches apart , sha ll be used through th e

covering to fasten the edge struts of the sides to the edge struts of the ends;

the st ru ts, diagonals, an fillers of the sides to the edge longitud inal members

of the top; the end crossmembers of the top to the upper frame members of

the ends; the u pper, lower, an d h orizontal mem bers, diagona ls, and fillers of the en ds to the edge stru ts of the sides; the lower frame m embers of the en ds

to the end headers of the base; and, the struts, diagonals, and fillers at the

lower edge of th e sides to th e skids of th e base. The covering of th e top shall

be nailed to the filler of the sides with fourpenny nails spaced 4 to 6 inches

apar t. When demount ability is specified, th e sides and en ds shall be fasten ed

to the ba se with lag bolts.

ASSEMBLY INSTRUCTIONS (MIL-C-52950)When specified, the contr actor sha ll fur nish applicable assem bly instru ctions.

T o l e r a n c e s

A tolerance of plus or minus 1/8 inch is allowable on the overall length and

width of individua l crat e pan els. Out -of-squa re deviations of individua l

panels shall be not more than 3/16 inch (3/8 inch different in diagonals).


Crate panels shall be clean and free of slivers and protruding nail points.

Crate panels be square and free of cracks, splits, or other damage which

would prevent easy an d corr ect a ssembly.

Table 6-8. Member Sizes an d Spacing for Type III, Style B Crat es

Member Size Member spacing

Depth of Cra te Width of Crate Length of Cra te

Member 0-8

inches

Over 8 to 12

inches

Over 12

inches

0 to 24

inches

over 24

inches

0 to 10

feet

Over 10 to

20 feet

Over 20

feet(inches) (inches) (inches) (inches) (inches) (feet) (feet-

inches)

(feet)

Longitudinal

members

1 X 3 1 X 4 1 X 6

Vert ica l end cleats 1 X 3 1 X 4 1 X 6

Horizonta l end

cleats

1 X 3 1 X 4 1 X 6

Top and bottom

crossmembers

1 X 4 1 X 6 2 2-6 3

Rubbing st r ips 3 X 4 3 X 6




6-59

Table 6-9. Fr am e Member Sizes for sides of Type V, Style B Crates

Limits of Dimensions and Net Loads Member Sizes (nominal)

Max. Strut. Spacing (on

center)

Longitudinals

Length Net Load Single

Panel

Double &

TriplePanel

Upper Lower Intermedia te St ru ts Diagonals

(foot) (pound) (inch ) (inch) (inch ) (inch) (inch) (inch ) (inch )

12 300 42 42 1 x 4 1 x 3 1 x 3 1 x 31 1 x 4

32 500 48 54 1 x 6 1 X 4 1 X 4 1 x 41 1 X 4

28 1000 42 54 1 x 6 1 x 4 1 x 4 1 x 41 1 x 4

24 2000 36 48 1 x 6 1 x 6 1 x 6 1 x 6 1 x 6

20 3000 36 48 1 x 8 1 x 6 1 x 6 1 x 62 1 x 6

16 4000 36 42 1 x 8 1 x 8 1 x 8 1 x 8 1 x 8

1 For edge stru ts use 1 x 4 except tha t 1 x 6 members sh all be used when edge stru ts of ends ar e 2 x 4 inches in size.2 For edge struts use 1 X 8 members.

Table 6-10. Num ber a nd size of Lag Bolts Required to Assemble the Base (Demounta ble Base) of Type V, Style B Crates

Total Minimum N umber of Lag Bolts

Size of Both for Ea ch Skid Size

Gross Weight (Crate a nd

Contents

5/16 X 3 inch bolt for 2X3

or 2 X 4-nch skid (flat)

3/8 X 3 inch bolt for 3 X 3

inch skid

1/2 X 3-1/2- inch lag bolt for 4

X 4-inch or two 2 X 4-inch

skids (on edge and lam inated)

pounds

1000 8 8 6

2000 14 10 10

3000 18 16 12

4000 24 20 14

5000 30 26 18

Table 6-11. Classification of MIL-C-3774 Crat es

Assembly

Maximum

net load (lb)

Maximum dimensions

Length Width Height

Type I,Nailed1

12,000 16 8 8

Type II,

Bolted2

16,000 40 8 16

1 Nailed assem bly - nondemount able.2 Bolted a ssembly - demountable.




6-60

OP EN WOOD CRATES , MIL-C-3774 (GENE RAL)

C RATE DESIGN

The open crates covered by MIL-C-3774 consist of framing members partially

sheat hed in specified area s. This sheath ing is applied to protect th e enclosed

item and acts as a reinforcement to the sides, ends, and top of the crate.These cra tes are designed to carry large or hea vy items. A minimum of 1-

inch clearance is required between the item and the nearest framing member

of the sides, ends, and top.


Crat es designed un der t his specification m ay be either bolted or na iled (table

6-11).

O p e n B o lt e d C r a t e s ( De m o u n t a b l e )

These crates are designed to withstand a superimposed load of 200 pounds

per squar e foot on the top, including dunna ge. These crat es may be used as

reusa ble conta iners.

O p e n N a i l e d C r a t e s ( No n d e m o u n t a b l e)

Crates designed under this classification are considered to be "one trip"

containers. This type ma y be constru cted with a skid-or sill-type base.

L u m b e r R e q u i r e m e n t s

Lumber

Lumber used in crate construction must meet the same rigid requirements as

for oth er wooden cont ainers. Lumber u sed in cra te constr uction sh all be free

of defects th at would ma terially weaken t he conta iner.

Plywood

Requirements for plywood are stated in A-A-55057.

Fasteners

Nails, strapping, bolts, etc., are commonly used.

OP EN B OLTE D CR ATES (MIL-C-3774)


Demountable crates are designed and constructed so that the major

components may be readily assembled or disassembled without damage to

the component pa rts. This is accomplished th rough th e use of lag bolts or

bolts (fig 6-5).

F a b r i ca t i o n o f Op e n B o lt e d C r a t e s

S k i d b a s e

S k i d s

The size of the skids is based upon t he n et load and the out side length of th e

crat e, as sta ted in table 6-12. The nu mber of skids are dictat ed by the item

being packed. However, the clear distan ce between any adjacent skid is

limited t o 48 inches cent er t o cent er (fig 6-39).




6-61

Figur e 6-38. Type V, style B crat e (MIL-C-52950), open an d covered.




6-62

To prevent splitting, place one carriage bolt crosswise to two to three inches

back from each end of th e skid (fig 6-39). When n ecessary, splice and

laminat e skids a ccording t o the details shown on figure 6-55.

R u b b i n g St r i p

Rubbing strips are required on all 4 X 4-inch skids and must be at least 2

inch material, approximat ely as wide as the skid. Bevel these member s at a45o angle and set back approximately 8 inches from the ends of the skids.

Bevel the inner ends of the notches at a 45o an gle. These areas will serve as

sling points and for forklift entries.

H e a d e r s

The sizes of end headers and bolts are outlined as follows:

Skid size Header size Bolt diameter

(inches) (inches) (inches)

2 X 4 2 X 4 3/8

3 X 3 3 X 3 3/8

4 X 4 4 X 4 1/24 X 6 (in edge) 4 X 4 1/2

Extend headers beyond the outside faces of the outer skids three-fourths of

an inch to support th e lower frame m embers of the sides.

Figur e 6-39. Skid base for bolted cra te (MIL-C-3774).




6-63

L o a d B e a r i n g F l oo r b o a r d s

Place load bearing floorboards wher e the concentra ted loads. Determine t he

size of load bear ing floorboar ds from ta ble 6-4. The en d floorboards of 2 inch

flooring may be considered as load-bearing within limits of their within limits

of th eir assigned values. The load-bearing members sh all be placed with t he

ends flush with the outside faces of the skids, as shown in figure 6-39, and

bolted to each skid with carriage bolts. One bolts sha ll be used at each skidcrossing for widths not exceeding 4 inches and two bolts, for greater widths.

Size of carriage bolts shall be the sam e as th ose used in th e end hea ders.

For k l i ft Ar ea

The forklift area extends over the area of 42 inches in from the ends of the

skids a nd ma y consist of the following:

ο Forklift h eaders spa ced 20 to 40 inches in from each end header .

ο 2-inch-thick boards extending 42 inches in from each end.

ο Plywood for narrow crates.

Di agona l s

1 X 6-inch diagonals are used between forklift areas and loadbearingmembers. The diagona ls are nailed to the skids and to each other where th ey

intersect.

Si des

The sides consist of upper, lower, an d inter mediate m embers, vertical str uts,

diagonals, and corn er shea thing.

S id e P a n e ls

The design of th e side pan el is illustra ted in figure 6-40. The nu mber of

diagonals will depend up on th e size of the crat e.

M em ber Se lec t i on

The sizes of the upper, lower, and intermediate longitudinal members are

based upon th e gross weight an d length of th e crat e as sta ted in ta ble 6-13.

Table 6-12. Skid Sizes of Bolted MIL-C-3774 Crat es

Maximum Net Load Maximum length of cra te Size of skids

Pounds Feet Inches

2,000 12 3 x 4

4,000 140 4 x 4

5,000 20 4 x 4

10,000 16 4 x 4

5,000 32 4 x 6 (on edge)

16,000 20 4 x 4 (on edge)

1 For lengths over 32 feet, crat e heights sh all be no less than 8 feet.




6-64

Table 6-13. Fr ame-mem ber Sizes (Sides of Bolted Crat es)

Limits Size of members

Length Net load Upper

frame

members

Lower

frame

members

Horizontalbrace

Feet Pounds Inches Inches Inches

212 500 35/8 x 4 35/8 x 4 35/8 x 4

10 2,000 1 x 4 1 x 4 1 x 4

16 4,000 1 x 6 1 x 6 1 x 6

12 8,000 1 x 6 1 x 6 1 x 6

440 4,000 2 x 4 2 x 6 2 x 4

16 10,000 2 x 4 2 x 6 2 x 4

20 10,000 2 x 6 2 x 8 2 x 4

20 16,000 2 x 8 2 x 10 2 x 8

NOTES: 1/ For crates of 48 inches and over2/ Size limit s of crat es. In add ition to th e 12 foot length an d 500

pound gross weight limit, this cra te ha ving 5/8 inch member s sha ll

be limited to 4 foot widths an d 6 foot heights m aximum .

3/ Actua l thickness of mem bers equals 5/8 inch.

4/ Crat es over 32 feet in length shall be not less than 8 feet in height.

Open bolted crates can not be fabricated in length s over 32 feet if the

height is less than 8 feet. Long crates less than 8 feet high shall be

fabricated in accordan ce with th e requ iremen ts of MIL-C-104.

Figur e 6-40. Side for bolted crat e (MIL-C-3774).




6-65

Di agona l s

Use 5/8 X 6 inch diagona ls for cra tes n ot exceeding 12 feet in len gth , 4 feet in

width an d 6 feet in height, with a maximum net load of 500 poun ds. Use 1 X

8 inch for cra tes exceeding 32 feet in lengt h a nd 12 feet in height . Use 1 X 6-

inch for all other conditions. See ta ble 6-14 for the spa cing of th e diagonals.

One-half of the diagonals shall be nailed to the outside of the longitudinal

frame members and the other half shall be nailed to the inside of the samemem bers, sloped in the opposite direction. The points of fasten ing of th e

diagonals, except at the end ones, to the longitudinal members shall be the

same for inside an d outside diagona ls to permit th e same lag bolts or bolts to

pass thr ough both diagonals. At the ends of th e upper and lower fram e

members wh ere no diagona l is present on the inside sur face of the member, a

filler block 12 inches long, the same thickness as one diagonal and the same

width as the frame member, shall be used to provide continuous bearing.

The n um ber of diagonals is determ ined by th e spacing of the diagonals.

Both inner and outer diagonals shall be nailed to each 2-inch horizontal

member with sevenpenny na ils in pat tern s as shown on figure 6-50.

The outer diagona ls shall be nailed to each 1-inch h orizontal mem ber with sixnails, thr ee driven from each side, and clinched.

The inner diagonals shall be nailed to each horizontal member with

sevenpenny na ils as shown on figure 6-40. When 5/8-inch frame mem bers

are u sed, the na il sizes sha ll be reduced as required.

Ve r t i c a l St r u t s o r C o r n e r P o s t s

Fabr icate th ese members from not less than 3 X 3-inch mat erial. These

pieces must be continuous from the upper longitudinal frame member of the

side to both the lower longitudinal frame member of the side and the end

floorboard m ember. Notch th e members wh en th e top of the end floorboar d

does not come even with t he t op of the lower longitudinal m ember of the side.

Corner posts or vertical struts are designed to receive the lag bolts from the

ends of th e crate.

C o r n e r S h e a t h i n g

Locate this mater ial on th e out side at each corner of th e cra te. Boar ds used

at each end of the sides must be at least 1 X 8-inch pieces, except when

diagonals a nd a re 5/8-inch-thick, the shea th ing is 5/8 X 8-inch mat erial. Nail

sheathing boards to the vertical struts and corner posts with two rows

(staggered patt ern) of ninepenn y na ils. Space 8 inches apar t within each

row. Nail sheath ing board s to 2-inch longitu dinal members with clinched

eight penn y nails, five at each joint. Secure t o 1-inch longitudina l members

with clinched nails. Use pat tern shown in figure 6-50.

E n d s

The ends consist of the upper, lower and intermediate longitudinal members

which are the same size as the corresponding members of the sides (fig 6-41).

Intermediate longitudinal members are required only when crates are 48

inches high or higher. Vertical strut s of the ends ar e one continu ous piece.

All diagonal members of the en ds are n ot less tha n 1 X 6-inch m ater ial. An X

frame pattern is required when the width of the crate is not more than 1 1/2

times the height. When this limit is exceeded, a two-X frame pat tern is

required.




6-66

P a r t i a l S h e a t h i n g (C o r n e r )

The outside vertical sheathing boards are not less than 1 X 6 inch for net

loads up to 3,000 pounds, and not less than 1 X 8 inch boards for net loads

over 3,000 poun ds. Nail the corner board t o the str uts with t wo rows of

sixpenny na ils (staggered patter n). Space th en 8 inches apart in each row

an d clinch.

Top P a n els ( fig 6-42)

Determine the number of panels to use by the length and width of the crate.

Place the diagona l fra me members a s near to 450 angles as possible.

F r a m e Me m b e r s

Use 2 X 4-inch (one edge) or 3 X 3 inch members for contents up to 4,000

pound s. Over 4,000 pound s, use 4 X 4 inch pieces. Na il 2-inch crosswise end

members with twelvepenn y na ils, th ree at each joint . Nail through th e side

grain of the edge member into the end gra in of the en d member. Nail 3 X 3-

inch and 4 X 4 inch crosswise end members with telvepenny nails, three at

each joint, toenailed from t he edge m ember int o the crosswise end member.

D i a g on a l M e m b e r sAll diagona l mem bers ar e 1 X 6 inch boar ds. Na il diagona ls to longitud ina l

members with eightpenny nails. Where diagonals cross each other, use

sevenpenny nails, five at each crossing, and clinch.

E n d S h e a t h i n g B o a r d s

All end sheath ing boar ds of the top are 1 X 8 inch in size. Nail the en d

sheat hing boards to the fram e member of the top with two rows of eight penn y

nails spaced 4 inches apa rt in a single line for 2 X 4 inch fram e members. For

larger members the na ils ar e staggered. Nail sheat hing board s to

longitudina l members with eightpenn y nails.

Table 6-14. Spa cing of Diagonals for MIL-C-3774 Crat esMaximum

spacing

Thickness of

longitudinal

members

Crate size

Height Width

Inches Inches Feet Feet

24 2 to 6 to 6

18 2 6-12 6-8

118 2 12-16 to 5

24 1 to 6 to 4

18 1 6-12 4-8

1 For crates over 32 feet in length.




6-67

Figur e 6-41. En d for bolted crat e (MIL-C-3774).

Figur e 6-42. Top for bolted cra te (MIL-C-3774).




6-68

Fi l le r S t r i p s

Fabr icate filler strips from 1 X 4-inch material. Place them between th e

diagonals an d na il. This will level th e top in ord er to accomm odate

superimposed loads. Secur e these str ips with sixpenny n ails spaced 6 inches

apart .

T o p J o is t s

Determine the size of the top joists by the width of the crate and the net

weight of cont ent s as sp ecified in ta ble 6-15. A single joist sh all be placed

between the longitudina l frame members an d at the center of balance. For

long crates or for crates over 10,000 pounds in weight, two sets of joists shall

be used and placed not more than 43 inches on each side of the center of

balance. Nail through th e 2 inch longitu dinal members into the end grain of

the t op joist with t welvepenny coated n ails, th ree in each joist. For 4 inch

joist, use five na ils. Toenail joist with t welvepenn y coated n ails.

ASSEMBLY OF BOLTED CRATES

Requ i r em en t s fo r Lag Bo l t s o r Bo l t sLag bolts may be used as fasteners for assembling the various panels of a

bolted cra te (fig 6-5). When a single diagonal occurs on th e inside of a

longitudina l member, use a thr ee-four ths inch shorter lag bolt or bolt. When

the diagona l is on t he outside of the frame m ember, use a 3/4-inch filler st rip

between the frame member and the member to which the part is being

fasten ed (fig 6-41). If bolts ar e used, they mu st be machine bolts with

washers placed under both the head and the nut . Use washers under the

hea ds of all lag bolts. Spa ce 3/8-inch lag bolts or bolts not more t ha n 24

inches apa rt. Space 1/2-inch lag bolts or bolts not more th an 30 inches a par t.

Space 5/8-inch lag bolts or bolts m ore tha n 36 inches a part .

Assembly of the panels (fig 6-43).

F a s t e n i n g t h e S id e s t o t h e B a s e

The size and number of lag bolts used to fasten the side panels to the base

are determined by the weight contents, the wood group used, and the width

and t hickness of the m embers as specified in ta ble 6-13. The nu mber of lag

bolts or bolts specified in the tables are given for both side panels, one-half

the n umber t o be used on each side.

Conn ector plates may be used between the diagona ls and skids. When used,

use only ha lf th e nu mber of lag bolts or bolts specified in ta bles 6-20 an d 6-21.

As an example, if the gross load is 8,000 pounds, use the number of bolts

required in tables for 4,000 pounds. Use th e correct diameter an d length of

fasteners specified in tables 6-16 or 6-17, through each pair of diagonals,

through the lower longitudinal member of the side, and into the sides of theskids.

F a s t e n i n g t h e S id e P a n e l s t o t h e T o p

Determine the size and number of lag bolts or bolts used to fasten the side

pan els to the t op from th e thickness of th e diagona ls and t op fram e members

of th e side, and t he width of the longitu dinal fra me member of the t op. Use

1/2-inch lag bolts or bolts when the combined thickness of the diagonals, the

upper edge member of th e side, an d th e longitudina l member of the top, is 4-

3/4 inches or more; use 3/8-inch fasteners when th e sum is less.




6-69

The length of the lag bolt should be approximately equal to the sum of the

thr ee or four thicknesses. Bolts should be long enough t o accommodat e the

nut a nd washers (under head an d nut).

Secur e the side pa nel to the t op by using a lag bolt or bolt t hr ough each pair

of diagonals and upper longitudinal member of the side, and into the

longitudina l member of the top. This is required aroun d the perimet er of thecrat e (fig 6-5).

Table 6-15. J oist Sizes

Size of joist Limits

Gross load Length (cra te

width)

Inches Pounds Inches

2 x 4 1,000 72

2 x 4 2,000 60

2 x 4 3,000 48

2 x 4 5,000 36

4 x 4 10,000 196

24 x 4 16,000 96

1 Use two joists for great er width s of top.2 Use two joists.

Table 6-16. Num ber of Lag Bolts for Assembling Sides to Base of Bolted Cra tes; Where Nominal 1-inch Longitudina l

Members

Are Used in S ides and N ominal 4-inch Wide Skids Are Used1/2 by 6-inch lag 1/2 by 5-1/2-inch lag 3/8 by 6-inch lag 3/8 by 5-1/2-inch lag

Net load 1/

Pounds

G1

I

G

II

G

II I

G

IV

G

I

G

II

G

II I

G

IV

G

I

G

II

G

II I

G

IV

G

I

G

II

G

II I

G

IV

8,000 28 24 22 18 32 28 24 22 32 28 26 22 36 32 30 26

7,000 24 22 18 16 28 24 22 18 28 24 22 20 32 28 26 22

6,000 20 18 16 14 24 20 18 16 24 22 18 16 28 24 22 18

5,000 18 16 14 12 20 18 16 14 20 18 16 14 22 20 18 16

4,000 14 12 10 10 16 14 12 10 16 14 12 10 18 16 14 12

3,000 10 10 8 6 12 10 10 8 12 10 10 8 14 12 10 10

1/2 by 5 inch lag 3/8 by 4-1/2 inch lag

3,000 18 16 14 12 20 18 16 14

2,500 14 12 12 10 16 14 12 10

Note. Refers to the wood group and applies to the skids. If bolts ar e used, they shall be the same nu mber a nd diamet er

as given for lag bolts.




6-70

Figur e 6-43. Assembly details for bolted crat es (MIL-C-3774).




6-71

Table 6-17. Nu mber of Lag Bolts for Assembling Sides to Base of Bolted Crat es; Where Nomin al 2-inch Longitu dina l

Members Are Us ed in Sides and N ominal 4-inch Wide Skids Are Used

Net load 1/

5/8 by 7-inch lag 1/2 by 7-inch lag 1/2 by 6-1/2-inch lag 1/2 by 6-inch lag

G

I

G

II

G

II I

G

IV

G

I

G

II

G

II I

G

IV

G

I

G

II

G

II I

G

IV

G

I

G

II

G

II I

G

IV

Pounds

16,000 48 44 36 32 56 48 44 36 64 56 48 44 74 68 60 52

14,000 40 36 32 28 48 44 36 32 56 48 44 36 64 60 52 44

12,000 36 32 28 24 40 36 32 28 48 40 36 32 56 52 44 40

10,000 30 26 24 20 34 30 28 24 40 34 32 26 46 42 38 32

9,000 26 24 22 18 30 28 24 22 36 32 28 24 42 38 34 28

8,000 24 22 18 16 28 24 22 18 32 28 24 22 38 34 30 26

7,000 20 18 16 14 24 22 18 16 28 24 22 18 32 30 26 22

6,000 18 16 14 12 20 18 16 14 24 20 18 16 28 26 22 20

5,000 14 14 12 10 18 16 14 12 20 18 16 14 24 20 18 16

4,000 12 10 10 8 14 12 10 10 16 14 12 10 18 16 14 12

3,000 10 8 8 6 10 10 8 8 12 10 10 8 14 12 12 10

1Refers t o the wood groups and a pplies to the skids.

Note. If bolts ar e used, they shall be the same nu mber a nd diamet er as given for lag bolts.

Table 6-18. Skid Sizes for Nailed MIL-C-3774 Crat es

Ma xim um net loa d Maxim um length of cra te Size of skids

Pounds Feet Inches

500 12 2 X 4

2,000 12 3 X 3

10,000 16 4 X 4

12,000 16 4 X 6 (on edge)

Table 6-19. Size of Side and E nd Sills

Net weight of

contents

H eigh t in feet Len gt h of cr at e (feet )

4 8 12 16

Pounds

2,500 to 4,000 Over 3

3 or un der

2 X 4

2 X 8

2 X 4

2 X 8

2 X 6

2 X 6

2 X 6

2 X 6

4,001 to 6,000 Over 33 or un der

2 X 42 X 8

2 X 62 X 6

2 X 62 X 6

2 X 62 X 6

6,001 to 8,000 Over 3

3 or un der

2 X 6

2 X 6

2 X 6

2 X 6

2 X 6

2 X 6

2 X 8

2 X 10

8,001 to 10,000 Over 3

3 or un der

2 X 6

2 X 6

2 X 8

2 X 10

2 X 8

2 X 10

2 X 8

2 X 10

10,001 to 12,000 Over 3

3 or un der

2 X 8

2 X 10

2 X 8

2 X 10

2 X 10

2 X 12

2 X 10

2 X 12




6-72

F a s t e n i n g t h e E n d P a n e ls

The diameter and length of th e lag bolts or bolts for fasten ing th e ends of the

crate to the top, bottom, and sides, is determined in a manner similar to that

for fasten ing the sides to th e top.

E n d P a n e l s t o t h e T o p

The size and length of fastener will depend upon t he t hickness of one or twodiagonals or fillers, the top horizontal frame member of the end, and the

width of th e crosswise fram e member to the t op.

E n d P a n e ls t o t h e B a s e

The size an d length of fasten ers for securing th e end pa nels to the base is th e

same a s above.

E n d P a n e l s t o t h e S i d e P a n e l s

The size an d length of fasteners to secur e the en d pan els to the side pan els is

as specified for fastening t he sides to the t op. For 5/8-inch fram e in th e end,

for loads not exceeding 500 pounds, use 5/16-inch diameter lag screws or

bolts.

C o r n e r S t r a p p i n g

Use corner strapping on all nailed and bolted crates carrying a net load of

3,000 pounds or over, to reinforce the corners a nd to reinforce the crat e at th e

jun ction of th e pan el (fig 6-4). Fa bricate a ll corner str aps from 1-1/4 X .035-

inch st eel banding, 12 inches in length.

Apply three straps on each of the four upper corners of the crate and secure

to the frame members with sixpenny nails, four in each leg of the strap.

Space approximately 2 inches center to cent er.

Apply single stra ps at 36-inch intervals from th e corner s in all directions an d

nail to the frame mem bers.

OP EN NAILED C RATES (MIL-C-3774)


Nondemountable crates may be designed with either a sill or skid-type base,

depending upon th e requiremen ts for th e item being packed.

S k i d B a s e s

Skid bases for open nailed crates are constructed almost identical to the

bases used for bolted crat es (fig 6-39).

Sk i d S i ze s

The size of skids depends upon th e net load an d th e length of the crate (table6-18).

H e a d e r s

Header s are bolted to the skids with carr iage bolts. The sizes of end h eaders

an d bolt sizes are as follows:




6-73

Skid size Header size Bolt diameter

(inches) (inches) (inch)

2 X 4 2 X 4 3/8

3 X 3 3 X 3 3/8

4 X 4 4 X 4 1/2

4 X 6 4 X 4 1/2(on edge)

Set the headers or end floorboards back from the ends of the skids the

thickness of the end sheathing. When necessary, notch the header s at their

ends down flush with t he top of the floorboard s. These notches will th en

accommodate and support th e lower edge members of the sides. Extend t he

header s to the outside faces of the outer skids. The end of the base will be

similar to th e base of th e MIL-C-104 crat e (fig 6-53).

L o a d B e a r i n g F l oo r b o a r d s

See t able 6-4 for s izes.

For k l i ft Ar eaRefer to th e requiremen ts sta ted in bolted crate section.

Nonl oad Bea r i ng F l oo r boa r d s (Di agona l s)

Refer to th e requiremen ts sta ted in bolted crate section.

Si l l Base s

Sill bases are designed for loads to be transmitted to the sides by means of

inter media te sills or by th e end sills. The size of th e side sills is based u pon

the weight of the conten ts an d th e length of the crat e. However, sill spacing

shall not exceed 48 inches center to center , whether required for tr an smitting

loads or for bracing (fig 6-44).

Si de and En d S i ll s

The size of th e side sills is obta ined from table 6-19. En d sills are t he sa me

size as th e side sills. Overlap the side sills over the en d sills an d na il at th e

corners using twent ypenny coated n ails. When necessary, lamina te the sills.

I n t e r m ed i a t e S il ls

Apply inter mediate sills either crosswise or lengthwise of the crate. These

members a re always required wh en th e width of th e cra te exceeds 48 inches.

Determine the size by the length of the sill and the actual weight supported

by the sill. Refer to ta ble 6-31 to calcula te th e inter media te sill size.

Attach intermediate sills at their ends to the side or end sills by a

combina tion of nailing an d meta l han gers (strap or stirru p) (fig 6-16). Metalhan gers ar e not required for fastening n onload bear ing intermediat e sills.

B r i d g i n g

Use bridging to prevent the sills from buckling and to strengthen the base.

Bridge intermediate sills at their ends, except when positioned on their flat

faces, with 1 inch lumber of th e same depth. Nail to th e inner face.

Reinforce spans 5 feet or over (either length or width of the crate) with 2 inch

lumber th e same depth a s the sills. Position the reinforcing members a t right

angles to th e sills.




6-74

Figur e 6-44. Sill base for n ailed crat e (MIL-C-3774).



F M 38-701/MCO P 4030.21D/NAVSUP P UB 503/AF J P AM 24-209/DLAI 4145.2

6-75

B o t t o m S h e a t h i n g

Position bottom sheathing and nail crosswise to the base (at right angles to

th e direction of th e side sills). Spa ce th e boar ds 1/4 to 3/8 inch apar t for

dra ina ge. Use boar ds 4 to 10 inches wide. For the fork lift area (42 in. from

each end of th e base) use 2 inch lumber. Use one piece sheat hing boards an d

extend them 1/2 to 5/8 of an inch beyond the outside faces of the side and end

sills. Place at least one diagonal in the un sheat hed portion of the base.


Position rubbing strips lengthwise to the crate under each longitudinal sill.

Rubbing strips are always 2 inches thick and not less than 4 inches wide.

The clear distance between rubbing strips should not exceed 30 inches. Cut

sling notches 8 inches long in ea ch end of the ru bbing str ip. Use filler strips

in the unsheathed area between the sil l and the rubbing strip where voids

occur.

Si des

The sides consist of upper and lower frame members, vertical struts,

horizontal braces, diagonals, and gusset plates (fig 6-45).

Des i gn o f t h e S ide P an e l s

Determine the design of the side panel from the inside length and inside

height of the crat e. For crates up t o 48 inches inside height use an X type

frame and for crates with an inside height of over 48 inches use a HK type

frame.


Determine the sizes of the upper and lower members, struts, and diagonals

from ta bles 6-20 and 6-21 with th e exception of the end stru t or corn er post.

Loads referred to in the ta ble are based on the n et weight of the cont ents a nd

th e inside dimensions of th e cra te. If th e exact size of th e cra te is not given in

the table, use the member size for the crate of the next longer length, the

neat greater width, an d next smaller h eight.

Use 1 X 4 inch lum ber for m embers a nd d iagonals a nd 2 X 4 inch lumber for

upper edge members when the height of the crate is 6 feet or less and the

load does not exceed 4,000 poun ds. Use 1 inch lum ber for th e lower edge

members, struts and diagonals, and 2 inch lumber for the upper edge

members and end str uts when the height of the crate is under 6 feet an d the

load is over 4,000 pounds. Use 2 X 4 inch lumber for t he u pper a nd lower

edge members, struts and diagonals, when the height of the crate is over 6

feet.

U p p e r , L ow e r , a n d I n t e r m e d i a t e M e m b e r s

The member s are requir ed to be a single cont inu ous piece. If splicing isrequired, splice the members according to the details shown in figure 6-54.

All splicing should be ma de un der or over a stru t wh enever possible. Splicing

1 inch ma terial is not perm itted. The size of these mem bers is based upon

the gross weight an d length of the crate. Int ermediat e members (horizonta l

braces) ar e used only for crates of the H K type.




6-76

Table 6-20. Pa nel Member Selection (6,000, 8,000 and, a nd 10,000 Pounds Net Load)1

4-foot width 6-foot width 8-foot width

Length Members Net load Height (feet) Height (feet) Height (feet)

2 4 6 8 2 4 6 8 2 4 6 8

Feet Pounds

6 Upperframe members 6,000 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4

Lower framemembers

6,000 ......... ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Struts 6,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Diagonals 6,000 ........ ......... ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

8 Upper frame member 6,000 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4

Lower frame member 6,000 ......... ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Struts 6,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Diagonals 6,000 ........ ......... ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4



Struts 6,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Diagonals 6,000 ........ ......... ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4



Struts 6,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Diagonals 6,000 ........ ......... ........ 2 X 4 ........ ........ ........ 2 x 4 ........ ........ ........ 2 X 4



Struts 6,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Diagonals 6,000 ........ ......... ........ 2 X 4 ........ ........ ........ 2 x 4 ........ ........ ........ 2 X 4



Struts 8,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Diagonals 8,000 ........ ......... 1 X 6 2 X 4 ........ ........ 1 x 6 2 x 4 ........ ........ 1 X 6 2 X 4



Struts 8,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4




Struts 8,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4




Struts 8,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Diagonals 8,000 ........ ......... 1 X 6 2 X 4 ........ ........ 1 x 6 2 x 4 ........ ........ 1 X 6 2 X 416 Upper frame member 8,000 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4


Struts 8,000 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4





6-77

Table 6-20. Panel Member Selection (6,000, 8,000 and, and 10,000 Pounds Net Load)1

(Continued)

4-foot width 6-foot width 8-foot width


2 4 6 8 2 4 6 8 2 4 6 8

Feet Pounds

6 Upper frame members 10,000 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4

Lower frame members 10,000 ......... ........ ........ 2 X 4 ........ ........ ........ 2 X 4 ........ ........ 2 X 4 2 X 4

Struts 10,000 ........ ........ ........ 2 X 4 ........ ........ 1 x 6 2 X 4 ........ 1 X 6 2 X 4 2 X 4

Diagonals 10,000 ........ ......... 1 X 6 2 X 4 ........ ........ 1 X 6 2 X 4 1 X 6 ........ 1 X 6 2 X 4


Lower frame member 10,000 ......... ........ 2 X 4 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Struts 10,000 ........ ........ 2 X 4 2 X 4 ........ ........ ........ 2 X 4 ........ ........ ........ 2 X 4

Diagonals 10,000 ........ 1 X 6 2 X 4 2 X 4 1 X 6 1 X 6 1 X 6 2 X 4 1 X 6 1 X 6 1 X 6 2 X 4



Struts 10,000 ........ ........ 1 X 6 2 X 4 ........ ........ 1 X 6 2 X 4 ........ ........ 1 X 6 2 X 4



Lower frame member 10,000 ......... ........ ........ 2 X 4 ........ ........ 2 X 4 2 X 4 ........ ........ 2 X 4 2 X 4

Struts 10,000 ........ ........ 1 X 6 2 X 4 ........ ........ 1 X 6 2 X 4 ........ ........ 1 X 6 2 X 4



Lower frame member 10,000 ........ ........ ........ 2 X 4 ........ ........ 2 X 4 2 X 4 ........ ........ 2 X 4 2 X 4

Struts 10,000 ........ ........ ........ 2 X 4 ........ ........ 2 X 4 2 X 4 ........ 1 X 6 2 X 4 2 X 4

Diagonals 10,000 1 X 6 1 X 6 1 X 6 2 X 4 1 X 6 1 X 6 2 X 4 2 X 4 1 X 6 1 X 6 2 X 4 2 X 6

1All blank spaces are 1 X 4's

Note. See text for size of end struts of sides.




6-78

Table 6-21. Panel-Member (Selection (12,000 Pound Net Load))1

4 foot width 6-foot width 8 foot width


4 6 8 4 6 8 4 6 8

Feet Pounds

6 Upper frame members 12,000 ........ ........ ........ ........ ........ ........ ........ ........ ........Lower frame members 12,000 ........ ........ ........ ........ ........ ........ ........ ........ ........

Struts 12,000 ........ ........ ........ ........ ........ ........ ........ ........ ........

Diagonals 12,000 ........ ........ (*) ........ ........ (*) ........ (*) (*)

8 Upper frame member 12,000 ........ ........ ........ ........ ........ ........ ........ ........ ........

Lower frame member 12,000 ........ ........ ........ ........ ........ ........ ........ ........ ........

Struts 12,000 ........ ........ ........ ........ ........ ........ ........ ........ (*)

Diagonals 12,000 ........ (*) 2 X 6 ........ (*) 2 X 6 ........ (*) 2 X 6



Struts 12,000 ........ ........ ........ ........ ........ (*) ........ ........ 2 X 6

Diagonals 12,000 ........ 2 X 6 2 X 6 ........ 2 X 6 2 X 6 ........ 2 X 6 2 X 6



Struts 12,000 ........ ........ ........ ........ ........ 2 X 6 ........ 2 X 6 2 X 6

Diagonals 12,000 ........ ........ 2 X 6 ........ 2 X 6 2 X 6 ........ 2 X 6 2 X 6



Struts 12,000 ........ ........ ........ ........ ........ 2 X 6 ........ ........ 2 X 6

Diagonals 12,000 ........ ........ 2 X 6 ........ ........ 2 X 6 2 X 6 2 X 6 2 X 6

NOTES:

1. All blank spa ces are 2/4's.

* The above sizes are for un iform loads but apply also to concentra ted loads where an aster isk is shown. When a sterisk

is shown, increa se the mem ber size to 2x6 for concentrat ed load.




6-79

Figur e 6-45. Side or en d pan el for nailed crat e (MIL-C-3774).

Ver t i ca l S t r u t s and Di agona l s

All vertical struts and diagonals are continuous from the lower frame

member to the upper frame member. Cut th e diagonal and horizontal braces

to fit between th e vertical stru ts.

E n d S t r u t s o r C o r n e r P o st s

The end vertical strut or corner post of the side is not less than 2 inches in

thickness in order to provide sufficient nailing space when fastening the

ends.




6-80

P a r t i a l S h e a t h i n g B o a r d s

Always apply th e sheath ing board s vertically. These board s are located a t

the corn ers an d at var ious inter vals based upon the design of th e cra te.

L u m b e r S h e a t h i n g

The shea thin g boar ds ar e of one piece mat erial, 1 inch t hick, and from 4 to 10

inches wide. All end boar ds ar at least 6 inches wide, preferably wider. Tenpercent of the boards may be 4 inches wide, but no narrow boards may be

adjacent to each other .

P l y w o o d S h e a t h i n g

Plywood strips, three or five ply material, may be substituted for lumber

sheat hing in th e sides, ends, or tops. This mater ial must be th e same width

as the lumber shea thing. For loads up t o 5,000 poun ds, use 7/16 inch

plywood of group I woods; 3/8 inch of group II woods; 5/16 inch of group III

an d IV woods. For loads over 5,000 poun ds, use 1/2 inch plywood of group I

woods; 7/16 inch of group II woods; 3/8 inch of group III and IV woods.

G u s s e t P l a t e s

Gusset plates are required for crates using 1 inch fram e members. Place th egusset plates where the diagonals, struts, or horizontal braces intersect.

Plywood gusset plates are not required when p lywood sheat hing is used. Use

12 X 12 X 1/4 inch gusset plat e for 1 X 4 inch fram e mem bers. Use 18 X 18 X

1/4 inch gusset plate for 1 X 6 inch fram e members. Secure t he gusset plat es

to frame members using sevenpenny nails and clinch (fig 6-45).

N a i li n g L u m b e r S h e a t h i n g

Nail 4 to 6 inches wide sheat hing boards of horizont al an d diagonal members

with thr ee rows of ninepenn y clinched nails. Use thr ee nails in sheath ing

boar ds 4 to 6 inches wide an d four na ils in wider board s. Nail sheath ing

boar ds over 6 inches wide to horizontal an d diagonal members with four r ows

of ninepenn y clinched nails. Nail sheat hing boards 4 to 6 inches wide to

vertical struts with two rows of ninepenny nails, spaced 6 inches apart in

each row an d clinch.

N a i li n g P ly w o o d S h e a t h i n g

Nail plywood sheath ing to 4 inch wide fram e mem bers with two rows of na ils,

spaced 6 inches apar t in each row, an d clinch. Use thr ee rows in frame

members over 4 inches wide. The na iling requirement s are ident ical to those

illust ra ted in figure 6-5 except for th e spacing.

E n d s

The end frame mem bers are identical to those of the sides. The design of the

end pa nels is also based upon th e inside length a nd inside height of th e crat e.

The pa nel design will be eith er X or HK fra ming (fig 6-45).


The frame members of the ends are the same size as the corresponding

members of the sides.

T o p P a n e ls

The top panels consist of framing members, partial sheathing boards, gusset

plat es an d joists. Tops are classified according to types (table 6-22 and fig 6-

46).




6-81

N u m b e r o f P a n e l s

To determine the number of panels for N, X or HK type of top, divide the

crate length by the crate width an d use th e nearest whole number.

F r a m e Me m b e r s

All top fra me members a re 1 X 6 inch m ater ial. When th e width of the t op is

24 inches or less use 1 X 4 inch material.

G u s s e t P l a t e s

Use gusset plates at the inter section of the fram e members of th e top. They

are the same size and nailed in the same manner as those for the side and

end panels.

T o p J o is t s

Determine the size of the joists by the weight of the contents and the length

of th e joists (table 6-15). Spa ce th e joists not more th an 48 inches center to

center . Extend a ll joists from the u pper longitudina l member of one side to

the u pper longitudina l member of the other side. Fast en each joist with t hr ee

twelvepenn y coated sinkers th rough th e upper edge mem bers of the side into

the end of th e joist when th e fram ing is one inch thick. Use thr eetwent ypenny na ils per joint for 2-inch upper frame member s. This nailing is

accomplished a s th e crate is being assem bled.

F ABRICATION OF OP E N NAILED C RATES

S h e a t h i n g t o th e H o r i z o n t a l a n d D i a g on a l F r a m e M e m b e r s

Use nails for securing the sheathing to the frame members (up to and

including 2-inch thickness) long enough to permit clinching at least one-

fourth of an inch. Use thr ee rows of na ils to secur e the sheath ing. Use a

minimum of thr ee nails in each shea thing board up t o 6 inches wide. Use not

less than four na ils in wider boards.

S h e a t h i n g t o t h e Ve r t i c a l F r a m e M e m b e r s

Use two rows of nails, placed on 6-inch centers, in each row and stagger

(table 6-24 an d figure 6-46).

P l y w o o d Sh e a t h i n g t o t h e F r a m e M e m b e r s

The n ails for fastening plywood to fra ming mem bers sha ll be long enough to

pass through the plywood and the frame member and be clinched not less

tha n one-four th of an inch. Sta gger all na ils in two parallel rows in each

frame member up to 3-5/8 inches wide, and in three rows in wider frame

members. Place the na ils not less tha n one-half of an inch from th e edge of

the frame mem bers. The distance between rows of na ils is not less tha n 1

inch, and the distance between adjacent nails in any row is not to exceed 6

inches.

S h e a t h i n g t o t h e S id e F r a m e M e m b e r s o f t h e T o p

Use two rows of na ils. One r ow th ree-four th s of an in ch from th e inside edge

of the frame member, and one row three-fourths of an inch from the outside

edge. Stagger th e nails between rows with a minimu m of two clinched na ils

in each shea thing board at each longitudina l member.




6-82

S h e a t h i n g t o t h e E n d F r a m e M e m b e r s o f t h e T o p

Place one row of nails in three-fourths of an inch from the inside edge of the

fra me member. Place the other row in the center of the frame member s.

Space the na ils 9 inches apa rt in each row and clinch.

S h e a t h i n g t o t h e L o n g i t u d i n a l a n d D i a g on a l M e m b e r s o f t h e T o p

Use three rows of nails, with not less than three nails in sheathing boards 6inches wide. Use not less than four na ils in wider boards.

S h e a t h i n g t o t h e S t r u t s o f t h e T o p

Two rows of nails are required not less than three-fourths inch from the

edges of both th e fra me members an d the sheat hing. Space the nails on 9-

inch center s in ea ch row and clinch.

P l y w o o d S h e a t h i n g t o t h e F r a m e M e m b e r s o f t h e T o p

If plywood is substituted for lumber, stagger the nails in two parallel rows

and space them 6 inches apart in each row. Position the nails three-fourths

inch from the edge of th e fra me members. The nails must be long enough to

penetr ate both th e members an d be clinched at least t hr ee-fourth s of an in ch.

Table 6-22. Type of Tops (MIL-C-3774)

Type framing pat tern Width of top (in .)

N........................ Up to 40

X........................ Over 40 through 60

HK....................... Over 60 through 96

Table 6-23. Na iled Crate Assem bly (MIL-C-3774)

Fasten Size type of na il Maximum spacing Notes

Par t To par t

Inches

Corner stru t of end - (1-

inch member)

Corner of strut of the

side

12d 12

Corner stru t of end - (2-

in. member)

Corner st ru t of the side 20d 12

Predril l through sheathing

of end a nd

Sheathing of side Corner st ru t of the end 8d 6 to 8 corner str ut of end.

Edge frame member of

top - (through shea thing)

Upper frame member of

sides

12d 6 cen ter to center Stagger

Edge frame member of

top

Upper frame member of

sides

8d 6 to 8 Space na ils between top

sheathing

End st ru t of top Upper fr ame member of

en d

12d 6 Stagger

Table 6-24. Nailed Per Each 1,000-Pound Gross Load; Nailing Side Shea thin g to Skids or Sills and E ndSheath ing to Headers and Sills

Nail Wood groups of skids

Type Penny size II III IV

Common 7 20 21 16

Sinker or cooler 7 23 26 19

Sinker or cooler 8 or 9 19 21 16

Sinker or cooler 10 18 19 14

Corker 8 or 9 17 19 14




6-83

Figur e 6-46. Types of top pa nels (MIL-C-3774).




6-84

ASSEMBLY OF OP EN NAILED CRATES (FIGS 6-4, 6-47 AN D 6-48)

N a i li n g R e q u i r e m e n t s

The na iling requirement s for fasten ing the base, sides, ends, an d top together

are foun d in tables 6-23 an d 6-24.

N a i li n g P r o c e d u r e s

When attaching the sides and ends to the skids, use one row of nails

(staggered ) for 2 inch-deep skids, two rows for 3 an d 4 inch-deep sills an d

thr ee rows for deeper members. Secur e the corn er stru ts of th e end to the

corn er stru ts of the side with t wentypenn y nails spaced 12 inches apar t. Nail

the partial sheathing of the side to the corner strut of the end using

eightp enny na ils, spaced 6 to 8 inches apa rt, an d staggered. Nail through th e

top sheath ing into the u pper edge members using twelvepenny nails spaced 6

inches apa rt, center t o cent er. Nail the top sheat hing to the top joists using

twelvepenn y nails, spaced 8 inches apa rt.

Cor ne r s t r ap pin gs (f igs 6-4 and 6-18)

SH EATHE D WOOD CR ATES, MIL-C-104 (GENE RAL)MIL-C-104 covers requirements for two types and two classes of sheathed

crates each of which may ha ve two styles of bases. The crates a re designed

for net loads not exceeding 30,000 pounds and to withstand the most severe

overseas shipping an d st orage conditions.

C LASSIFICATION

Eight crate designs are possible through the combination of the following

types, classes and styles. These crates a re a vailable in different type, classes,

an d styles. For exam ple a type I (na iled), class 2 (plywood shea th ed), Style A

(skid base) crat e ma y be used.

Type I - Na iled

Type II - Bolted

Class 1 - Lumber sh eath ed

Class 2 - Plywood sheathed

Style a - Skid base

Style b - Sill base

Wei gh t L i m i t a t i ons

The gross weight of these crates should not be more than 11,200 pounds

whenever pra ctical. This weight is recommended in order to permit han dling

with ship’s gear. However, when th is limitat ion is not possible, th e gross

weight ma y be great er tha n 11,200 poun ds but less than 20,000 poun ds for

crat es with S tyle B (sill) bases, or 30,000 pound s for cra tes wit h S tyle A (skid)bases.

Di m ens i on L i m i t a t i ons

The exterior dimensions of the crate shall not exceed the following

limitations, unless specified, for overseas shipment for which dimensions of

the Int erna tional Loading Gauge shall apply.

Length - 30 feet Width - 9 feet Heigh t - 10 feet




6-85

Figur e 6-47. Assembly of open n ailed crat es (MIL-C-3774).




6-86

Figur e 6-48. Assembly details for na iled cra tes (MIL-C-3774).




6-87

I n t e r i o r C le a r a n c e

A clearan ce of not less th an 1 inch shall be allowed between t he item and the

closest member of the sides, ends, and t op of the crate. Fr agile items or items

within floating bag barriers shall be protected with clearances of not less

tha n 2 inches. Additiona l clearan ces may be provided for shock mount ed

items. Protru ding parts at t he top may be allowed to extend between joists;

spacing of joists m ay be a djust ed slightly to accomm odate p rojections.

MATERIAL R EQUIREMENTS

M a t e r i a l

Mat erial sha ll be as specified herein . Mat eria ls not specified sha ll be selected

by the contractor and shall be subject to all provisions of MIL-C-104

specification.

L u m b e r

Lum ber component s sha ll conform to woods comm only used.

Pl ywood

Plywood shall conform t o A-A-55057 Type A or B. Plywood (type A or B) shallcomply with PS1 a nd P S2.

N a i ls a n d S t a p l e s

Nails an d sta ples shall be steel an d sh all conform to ASTM F 1667-95.

N u t s , a n d Wa s h e r s

Nu ts sha ll conform to FF -N-836, Type I or II, style 1 or 4. Wash ers sh all

conform t o FF-W-92, Type A, Grad e I, Class A.

S t r a p p i n g

Strapping shall conform to ASTM D 3953, Type 1 or 2 as applicable. Finish

sha ll be A, B, or C.

B a r r i e r M a t e r i a l

Barrier material, for crate liners, shall conforms to PPP-B-1055, class as

appr opriate for crat e liners.

C ONSTRUCTION

N a i li n g P r o c e d u r e

Na ils used sha ll be sink ers, coolers,, cork ers, or common. Na ils sizes

specified for the fabrication of the var ious crat es ar e based on Gr oups I an d II

woods. When Groups III or IV woods are used, n ails sizes ma y be onepenn y

size smaller tha n th ose specified. The pat tern s to be used for the n ailing of

two flat pieces of lumber shall conform to the details shown in figure 6-50).Unless otherwise specified herein, the following requirements shall

determine size, placement , and quan tity of nails:

• All adjacent crate members shall be securely fastened to each other,

either directly or by means of the covering.

• All na ils t hat are not t o be clinched sha ll be cement -coated.

• Nails shall be driven through the thinner member into the thicker

member wherever possible.




6-88

Figure 6-49. Ventilation end screening of sheat hed crat es.




6-89

Figure 6-50. Nailing pat tern s.

• Nails for fastening plywood to framing shall be clinched at least 1/4

inch. Hea ds of na ils sha ll alwa ys be on the plywood side.


combined thickness is 3 inches or less (except for top joists and

covering material), nails shall be long enough to pass through both

thicknesses an d sha ll be clinched n ot less th an 1/4 inch or more th an

3/8 inch.


combined th ickness is m ore tha n 3 inches or when th e flat face of one

or more pieces is nailed to the edge or en d face of another , na ils sha ll

not be clinched. The portion of th e nail in th e thicker piece shall not

be less than 2 times the length of the nail in the thinner piece fortenpenny nails and smaller, and not less than 1-1/2 inches for

twelvepenn y nails an d larger.

• When splitting occurs with the use of diamond-point nails, the nails

shall be slightly blunted. When blunting does not prevent th e

splitting, holes slight ly smaller th an th e diameter of th e nail sha ll be

drilled for ea ch na il.

• Nails shall be driven so that neither the head nor the point projects

above th e surface of th e wood. Occasiona l over-driving will be

permitted, but nails shall not be over-driven more than one-eighth

the thickness of th e piece holding th e hea d.




6-90

• Nails sha ll be positioned not less th an the thickness of the piece from

the en d an d not less tha n one-half the thickness of the p iece from th e

side edge of the lum ber whenever possible. Nails driven into the side

edge of lumber sha ll be center ed on th e side edge.

• Nails securing plywood sheathing to frame members shall be spaced

as shown in figure 6-51. Machine driven na ils having a definite head

may be u sed for securing plywood sh eath ing providing th ey meet sizerequiremen ts specified herein.

St ap l i ng

Staples may be used to fasten sheat hing to frame members. They shall not

be used for fabrication of bases, fastening of framing members to each other,

or for assem bly of crat es. Sta ples sha ll ha ve crowns of not less th an 3/8 inch

wide and shall have a wire diameter of not less than 0.062 inch (16 gage).

Straight leg staples shall be long enough to provide a minimum 1/4-inch

clinch. Divergen t point st aples sha ll not be less tha n 1 inch long. Spa cing of

staples shall be the same as for na ils. Stap les shall always be driven from

th e plywood side.

Bol t App l ica t ionHoles shall be prebored to receive carriage bolts and shall be the exact

diameter of the bolt. The lead holes for lag bolts shall be the sa me diamet er

as the sha nk, even th ough th e threaded portion ma y have a greater diameter

than the sha nk, and shall be as shown in ta ble 6-25.

Lag bolts shall be placed by being tur ned in their holes th e full length of the

bolt and sha ll not be driven in with a h amm er or by an y similar mean s. If,

for any reason, the thread in the wood is stripped when the lag bolts are

placed, the lag bolt shall be removed and placed in a new hole near the old

position. A flat wa sher sh all be used un der th e head of each lag bolt and

un der th e nut of each car riage bolt. After th e nut is placed, th e thr ead of the

carr iage bolt pr ojecting beyond t he n ut sh all be painted with a su itable metal

primer or similar m ater ial.

Vent i lat io n (figs 6-49 an d 6-51)

All crates shall be provided with ventilating holes or slots which shall be

located at each end or at ends and sides of lumber and plywood sheathed

crates, or around the perimeter of plywood and lumber sheathed crates.

These vent ilating holes or slots sha ll be locat ed immediat ely below the top

frame member and be provided with a baffle as shown in figure 6-51 when

slots are used in plywood sheathed crates or when holes are in clusters in

lumber sh eath ed crat es. Single holes drilled without baffles shall be sloped

at 45 degrees to drain outwar d. No holes or slots sha ll be cut in an y fram e

member.

Class 1 Crates

Class 1 crat es sha ll be provided with vent ilation holes, 3/4 inch in diameter .

The crate liner shall be removed from the ventilating area and all splinters

and chips shall be removed from th e holes.

En d Ven t i l a t i on

Ventilating holes shall be provided in each end in one or more clusters,

placed near the upper frame members, provided with a baffle, and spaced 2

inches on center as shown in figure 6-51. In sma ll crat es, holes may be

located so tha t diagonals or str ut s can be utilized in pa rt for cleats. In crates

over 10 feet in length , the ventilating holes shall be divided equa lly between




6-91

th e sides and en ds with a baffle pr ovided for each group of holes. The

clusters of holes shall be located as near the midpoint of the side and end as

pra ctical. The nu mber of holes shall comply with ta ble 6-26.

P e r i m e t e r Ve n t i la t i o n

As an alternate to end ventilation, the 3/4 inch ventilating holes may be

spaced evenly around the perimeter of the crate just under the top framemember an d drilled at a 45 degree angle to dra in outwa rd (fig 6-49). The

total number of holes shall comply with table 6-26.

Table 6-25. Lag bolt lead hole sizes.

Diameter of Threaded

Portion of Lag Bolt

(inch)

Diameter of Lead H ole (inch)

Groups I, II, and

III Woods

Group IV Woods

1/4 3/16 3/16

5/16 1/4 1/4

3/8 1/4 5/16

1/2 3/8 7/16

5/8 3/8 1/2

3/4 1/2 5/8

Table 6-26. Ventilat ion holes an d area requ ired.

Lumber -sheathed cra tes Plywood-sheathed

crates

Volum e of crat e

(cu. ft.)

End ventilation

minimum num ber of 3/4

inch diameter holes

required in each end(place in cluster an d use

baffle)

Perimeter ventilation

(alterna te) Total m inimum

num ber of 3/4 inch diameter

holes r equired aroundperimet er (space evenly an d

slope to drain out )

Area required in each

en d

(Use baffle and screen)

(sq. in.)

0-100 3 6 7

100-150 4 8 10

150-200 5 10 14

200-400 9 18 27

400-600 14 27 40

600-800 18 36 52

800-1,000 22 44 66

1,000-1,200 27 54 80

1,200 and over 33 66 100Note. In lar ge crates, where a lar ge ventilat ing area is requ ired, two or more slots or clust ers of holes may

be used in each panel.




6-92

Class 2 Crates

Class 2 crat es shall be provided with a h orizontal slot in each end. The

ventilation slots sha ll be provided with baffles and screens as shown in figure

6-51. The required ventilating area shall comply with table 6-26. In crates

over 10 feet in length, the ventilation area shall be divided equally between

the sides and ends of the crate with baffle and screen provided for each

ventilating area. The ventilatin g area sh all be placed as near th e midpointsof the sides and en ds as pra ctical. In sma ll crates, 3/4 inch diam eter h oles

may be su bstituted for th e slots in th e proportion of two holes for each squa re

inch of required ar ea.

Class 1 Crates

Class 1 crates may be either bolted or na iled. Bolted crat es shall be so

designed that the major components of base, sides, ends, and top may be

assembled to each other with lag bolts in order tha t th e crat e can be rea dily

disassembled and, if desired, reassembled without major dama ge to the par ts.

Nailed crates are assembled with nails and straps, are not easily

demountable, and because of probable damage during disassembly, are not

generally reused. A combinat ion of top, side, an d end pan els may be

fabricated an d assembled to each other a s specified for n ailed cra tes, an d th eun it fastened t o the ba se as specified for bolted crates.

B a s e s

Bases sha ll be designed t o support the weight of the crat ed ar ticle only when

the sides and en ds are fastened in place.

Sk i d Type ( St y l e a )

Style a bases shall consist of longitudinal skids and rubbing strips, headers,

load-bearing floorboards, and flooring as shown on figures 6-52 and 6-53.

Details of constru ction sha ll be the sa me for bolted an d na iled crates.

Table 6-27. Allowable minimu m skid sizes

Maximum

netload (lb.)

Maximum

length of crate

(ft.)

Nominal size of skids (in.)

300 16 2 X 4 (fla t) 1/

1,000 12 2 X 4 (fla t) 1/

2,000 20 3 X 3 or 3 X 4 (fla t ) 2/

10,000 32 4 X 4

30,000 20 4 X 6 (on edge)

1/ For nailed cra tes only.

2/ For crat es with 2-inch-thick lower fram e member or 2-inch end struts.




6-93

Figur e 6-51. Ventilat ion of lumber a nd plywood shea th ed cra tes (MIL-C-104).




6-94

Figu re 6-52. Skid ba se plywood floorin g (MIL-C-104).




6-95

Figur e 6-53. Skid base lu mber floorin g (MIL-C-104).

S k i d s

Any species of wood except Groups I sh all be used for skids. Skids sh all be

spaced no farther apart than 48 inches, center to center, across the width of

the base. Minimum size sha ll be as shown in table 6-27. When either the

length or net load exceed the maximum shown, the next larger skid shall be

used.

When necessary, skids may be spliced or laminated according to the details

shown in figures 6-54 and 6-55, but the use of 2 x 4 inch skids shall be limited

to such length s tha t no splicing would be required . When ever possible splices

shall be made not more th an one-third of the length of the ba se from th e ends

of the skid an d the splice locations alter na ted in adjacent skids. To prevent

splitting, all skids shall have a carriage bolt placed crosswise and 2 to 3

inches back from each end of th e skid as shown in figur e 6-55. Bolt sizes

sha ll comply with t able 6-28.




6-96

Figur e 6-54. Splicing of mem bers (MIL-C-104).




6-97

Figur e 6-55. Lam ina tion of skid or sill mem bers (MIL-C-104).




6-98

Table 6-28. Required header sizes and carr iage bolt sizes

Skid size

(in.)

Header size

(in.)

Bolt Diameter

(in.)

2 X 4 2 X 4 1/ 3 8

3 X 3 3 X 3 3/8

3 X 4

4 X 4 4 X 4 1/2

4 X 6

1/ For n ailed cra tes only in width t o 48 inches. For wider crates or

bolted cra tes, u se 3X3.

R u b b i n g S t r i p f or S k i d s

Rubbing strips of 3-inch thick lumber, the same width as the skids, shall be

att ached to the sk ids with two staggered rows of na ils spaced 12 inches apar t

in each row The nails shall be driven th rough the ru bbing strip into the skid,

shall be of such length as to penetrate a minimum of approximately 70

percent of the skid thickness, and sh all not protrude th rough the skid. The

strips shall be beveled full depth a t an an gle of 45 degrees at sling andfork lift openin gs. Openin gs in the rubbin g str ips for fork lift-tr uck access

shall be 12 inches in length, 28 inches center to center, and positioned to

stra ddle the center of balance of the loaded crate. Sling openings not less

tha n 4 inches in length, an d preferably 8 inches, shall be provided at t he en ds

of the rubbing strip where permitted by the length of the crate and by the

location of th e forklift-tr uck access open ings. No cent er pieces of th e ru bbing

stirps shall be less tha n 16 inches in length. On crates 5 feet and less in

length, th e forklift openings sh all be omitted; end sling openings sh all not be

less tha n 6 inches long a nd sha ll serve as both forklift a nd sling openings.

H e a d e r s

Headers shall be placed at each end of the base and shall be bolted to each

skid with one carr iage bolt. Sizes of header s an d bolts sh all be as shown in

ta ble 6-28.

For k l i ft Mem b er s

The forklift members shall consist of the header and two members of equal

size, spaced 20 to 40 inches (on center) from each end of the skids and bolted

as shown in figur e 6-52. Where th e form of the item to be cra ted ma kes it

impractical to use these members, or when crat es are sh ort or nar row, 2 inch-

thick lumber shall be used in the 48-inch end areas as shown in figure 6-52.

When 2-inch lumber is used in the forklift area and intermediate skids are

required because of the width of the base, the 2-inch forklift members shall

be bolted to the intermediat e skids. Forklift mem bers sha ll be notched or set

back a specified for head ers. If loaded conta iner s cent er of balan ce is oth ertha n t he center of the base, the spa ce for forklift entr y shall be positioned so

tha t t he center of balance is center ed in between forklift openings.

Headers shall be of a single piece and not built up to two or more pieces to

meet th e dimension requirem ents. Header s shall be placed atop the plywood

when p lywood floorin g is used. Hea der s sha ll be placed a dista nce back from

the en ds of th e skids equal to the th ickness of the en d sheat hing. The ends of

the headers shall be notched for bases floored with lumber; ends of headers

for plywood floored bases s ha ll be set back from th e outside ed ges of th e outer

skids (see figur es 6-52 and 6-53). The n otched and set back distan ces sha ll be

equal to th e th ickness of the lower fram e members of th e skids.




6-99

L o a d -b e a r i n g F l o or b o a r d s

Load-bearing floorboards shall be placed where the concentrated loads of the

cont ent s occur. The cross section sha ll be deter min ed from ta ble 6-29. The

forklift members and any 1 or 2 inch flooring may be considered as load-

bearing within limits of th eir assigned values. The ends of load-bearing

floorboar ds sha ll be notched or set back from t he edge of the base in the samema nn er as described for header s (see figur es 6-52 an d 6-53). Load-bearin g

floorboards 4 inches wide shall be bolted to each skid with one carriage bolt,

and load-bearing floorboards over 4 inches wide shall be bolted to each skid

with two carriage bolts, and the intermediate skid where one is required.

Bolt diameters shall be the same as specified for corresponding skid sizes.

L u m b e r F l oo r i n g

Lumber floorboards shall be neither less than 1 inch thick not less than 4

inches wide, an d shall be placed at right an gles to the skids. Boards sh all be

spaced 1/4 inch a part for dr ainage an d th e ends placed flush with th e outside

face of the skids. When a large area of the base is floored with 2-inch thick

lumber, the use of filler strips 2 inches wide shall be used along each side

over he thinner flooring to equal the thickness of the 2 inch flooring as shownin figure 6-53. The filler strips sha ll be nailed to the floorin g with t wo

staggered rows of sixpenn y nails spaced 10 inches apart . Nailing of

floorboar ds to skids sh all be as sh own on figur e 6-50.

P l y w o o d F l oo r i n g

Plywood 3/8 inch in thickness, may be used in place of 1 inch lumber flooring

as shown in figures 6-52 and 6-53, but not as load-bearing floorboards.

Plywood flooring shall be laid flush with the outer edges of the skids and with

the face grain perpen dicular to the skid length. Header s and load-bearing

floorboards shall be placed on top of the plywood and bolted to the skids after

th e plywood has been n ailed in place. Plywood flooring sha ll be nailed to

each skid with t wo rows of sevenpenn y na ils, staggered a nd spaced 6 inches

apa rt in ea ch row. A spa cing of 1/4 inch sha ll be allowed between s heet s of

plywood for dra inage. When 1/3 to 1/2 the ar ea of th e base is floored with 2

inch boards, the plywood flooring shall be used only between these areas.

Filler strips shall be nailed over the plywood as shown on figure 6-51 with

na iling a s specified.

D r a i n a g e

A drainage hole, 1/2 inch in diamet er, sha ll be drilled next to each hea der or

load-bearing member in each outer edge of plywood floored section of the

base. Holes should not be covered with conten ts ar e placed on the ba se of the

crate.

Si l l Type (Sty le b )Style b bases sha ll be const ru cted as shown in figure 6-56. The load

contained on Style b bases shall always be transmitted to the side sills by

mean s of int ermediate sills or by th e ar ticle itself.




6-100

Si de and En d S i ll s

The size of th e side sills sha ll be determ ined from table 6-30. En d sills sha ll

be of th e same size as side sills. The side sills sha ll overlap t he en d sills as

shown in figur e 6-56. Sills sha ll be lam inat ed as shown in figur e 6-55, when

necessary.

I n t e r m e d i a t e S i lls a n d L o a d -b e a r i n g H e a d e r sInt erm ediat e sills sha ll be app lied crosswise of th e base. The size of

interm ediate sills shall be determined from table 6-31. The weight u sed to

determine the size of an intermediate sill shall be that amount of the load

actually supported by that sill. Load-bearing headers sha ll be of the sa me

size as intermediate sills. Load-bearing headers an d intermediat e sills will

not be required when a ll of th e load is supported by the side sills. Load-

bearing headers shall be attached at their ends to intermediate sills and

intermediate sills shall be attached at their ends to side sills by a

combina tion of nailing an d th e use of metal str ap h an gers fabricated from 1-

1/4 inches wide by 0.035 inch t hick na il-on str app ing as sh own in figur e 6-57.

B r i d g i n g

Intermediate sills shall be bridged at the ends with 1-inch lumber and atintervals along the spa n n ot exceeding 4 feet with 2-inch lum ber of th e same

depth as th e inter mediate sills (see figure 6-56).

Table 6-29. Allowable load in lb per in ch of floorboar d width gr oups I an d II woods

Distance

between skids

(in.)

Thickness of load-bearing floorboard (in.)

3/4 1-1/2 2-2/2 3-1/2 5-1/2 7-1/2

12 57 287 600 1170 2900 5000

18 38 191 400 780 1930 335024 29 143 300 590 1400 2500

30 23 115 240 470 1160 2000

36 19 95 200 390 960 1680

42 16 82 170 335 830 1440

48 14 71 150 290 720 1250

54 12 63 030 260 645 1120

60 11 57 120 234 580 1000

66 10 52 110 212 525 910

72 9 48 100 195 480 840

84 8 41 85 140 360 710

96 8 35 75 167 300 630

108 7 34 66 130 233 560

120 7 30 60 117 210 500




6-101

Table 6-30. Nomin al size of side sills (in.)*

Gross weight of

cra te (lb.) Length of cra te (ft .)

4 8 12 16 20 24 28 32

to 2,000 2 X 4 2 X 4 2 X 4 2 X 4 2 X 4 2 X 6 2 X 6 2 X 6

2,001 - 4,000 2 X 4 2 X 4 2 X 4 2 X 4 2 X 6 2 X 6 2 X 6 2 X 8

4,001 - 6,000 2 X 4 2 X 4 2 X 4 2 X 6 2 X 6 2 X 6 2 X 8 2 X 8

6,001 - 8,000 .......... 2 X 4 2 X 6 2 X 6 2 X 6 2 X 8 2 X 8 2 X 8

8,001 - 10,000 .......... 2 X 6 2 X 6 2 X 6 2 X 6 2 X 8 2 X 8 2 X 10

10,001 - 12,000 .......... 2 X 6 2 X 6 2 X 8 2 X 8 2 X 8 2 X 10 2 X 10

12,001 - 14,000 .......... 2 X 6 2 X 8 2 X 8 2 X 8 2 X 10 2 X 10 2 X 10

14,001 - 16,000 .......... 2 X 8 2 X 8 2 X 8 2 X 10 2 X 10 2 X 10 2 X 8

16,001 - 18,000 .......... 2 X 8 2 X 8 2 X 10 2 X 10 2 X 10 2-2 X 8 2-2 X 8

18,001 - 20,000 .......... 2 X 8 2 X 10 2 X 10 2 X 10 2-2 X 8 2-2 X 8 2-2 X 8

* The above sizes ar e for cra tes with a h eight of 3 feet or less. For h eights of over 3 feet, increase 2X4 sizes

to 2X6; increa se 2X6 to 2X8; increa se 2X8 to 2X10; an d increa se 2- 2X8 to 2- 2X10.

Table 6-31 Allowable load for intermediate sills (in lb per inch of sill width)

Length of

sill (ft)

Sill depth (inch)

Groups I a nd II woods

1-1/2 2-1/2 3-1/2 5-1/2 7-1/2 9-1/2 11-1/2

4 71 150 290 720 1,250 2,000 3,000

5 57 120 234 580 1,000 1,640 2,400

6 48 100 195 480 840 1,320 2,020

7 41 85 167 399 710 1,170 1,730

8 35 75 140 350 630 1,020 1,500

9 34 66 130 300 560 910 1,350

10 30 60 117 270 500 820 1,200

B o t t o m S h e a t h i n g

Style b bases sha ll be sheat hed on th e bottom with lumber securely nailed to

the bottom surface of the sills at right angles to the direction of the side sills.

Boards shall be 4 to 10 inches wide and of not less than 1 inch material for

spans of less than 30 inches between longitudinal members and of not less

tha n 2-inch mater ial for spans of 30 inches or more. Bottom sheat hing shall

be flush with the outside face of all side and end sills and be spaced 1/4 inch

apar t fro drain age. One-inch board s shall be nailed with eightpen ny na ils, 2

inch boards with twelvepenny nails, and nailing shall be as shown in figure

6-50.

R u b b i n g st r i p s

Style b bases shall have rubbing strips 3 inch thick material, the width of

which sha ll not be less than 4 inches. The rubbing strips shall always be

applied lengthwise of the base and positioned under each longitudinal

member. When require, interm ediate rubbing strips of th e same size are

located so that the clear distance between rubbing strips does not exceed 36

inches.




6-102

Figure 6-56. Sill bases (MIL-C-104).




6-103

Figur e 6-57. Atta ching inter media te sills to side sills (MIL-C-104).

TopsTops sha ll be double sheat hed an d sha ll be

• na rrow, width s thr ough 54 inches;

• interm ediate, widths over 54 inches th rough 60 inches;

• wide, over 60 th rough 120 inches in width .

Plywood sheathing 1/4 inch thick, shall be attached to the lumber framing

with its face grain pa ra llel with th e width of the t op and its edges flush with

th e out side edges of th e fra min g. All joint s of th e plywood sheat hin g shall be

ma de over joists or oth er fram e member s. Roofing felt, or polyethylene film




6-104

not less tha n 4 m ils th ick, sha ll be applied over th e plywood with a m inimum

4-inch overlap at joints. A nonh ard ening caulk or mast ic sha ll be applied in

the overlap area. Top sheat hing board s not less tha n 4 inches wide shall be

placed over the plywood sheathing and waterproof barrier and shall extend

beyond the outer edges of the top framing by an amount equal to the

thickness of side and end pa nel sheat hing less 1/8 inch. Head ers joining the

joists t ogether shall be 1 inch th ick by th e depth of the joists for int ermediateand wide tops.

N a r r o w T o p s

Nar row tops shall be fra med on 2 X 4 inch mem bers as sh own in figur e 6-58.

Top shea thing board sh all be applied para llel to th e width of the t op and sha ll

be of single pieces. At plywood joints on t he in side of th e top, 2 X 3 inch

pieces shall be used as shown in figure 6-58.

I n t e r m e d i a t e To p s

Intermediate tops shall be framed on 2-inch joists placed flat and headers 1

inch by the t hickness of th e joists. The top sheat hing boards sha ll be placed

para llel to the length of th e top (see figur e 6-59). When th e crat e length is

over 10 feet, end joint s will be permitt ed in top shea th ing boar d. All joint sshall be made over joists, two joints sh all be adjacent to each other , and not

more th an one-th ird of th e joints sh all be made over a ny one joist.

Wide Top s

Wide tops shall be constructed similar to intermediate tops except that the

wide tops shall be framed in joists and headers placed on edge as shown in

figur e 6-60.

F a b r i ca t i o n N a i li n g

Fa brication na iling of tops sha ll be as shown in figur es 6-61 and 6-62. All

plywood mem bers sha ll be na iled on at least th ree edges.

Al t er n a t e P l yw o o d S h e a t h e d T o p

For tops not exceeding 96 inches wide, single sheathing of 1/2-inch thick

plywood ma y be used in lieu of th e double sheat hed t op. Face grain of the

plywood sha ll be para llel with th e width of th e top. When joists do not

coincide with plywood joints, a joint cover of 1 X 4 inch lumber shall be used

on the inside of th e top. Pr ior to securing th e plywood to th e joists or joint

covers, caulking of a nonhardening type shall be applied at three places at

each joint - between the plywood panels at their butt joint, and between the

plywood and joint cover or joist on either side of th e butt joint. The cau lk

shall be applied as a continuous bead a nd m ay be either performed or a pplied

with a gun.

Si des

Nu m ber an d Type of Pane l s

Sides sha ll be constr ucted as sh own in figures 6-63, 6-64, an d 6-65. In crat es

with style b bases, the sheathing of sides and ends shall reach below the

lower horizonta l fram e member a distan ce equal to th e depth of the sills plus

floor th ickn ess, less 1/8 inch. The type of side panels sha ll var y with t he

inside cra te height a s specified in table 6-32. The nu mber of pan els for each

full length side shall be computed by dividing the inside crate length by the

inside height, and using the nearest whole number.




6-105

Mem ber Select ion

The sizes of the upper and lower frame members, struts, and diagonals shall

be determ ined from tables 6-34 to 6-43 except a s other wise specified. Loads

referred to in the tables are the net loads and the dimensions are the inside

measu remen ts of th e crat e. The member sizes shall be based on Group II

woods. If th e exact size of th e cra te is not given in th e tables, mem ber sizes

for the crate of the next greater length and width, and the next smallerheight sha ll be used.

Upper and Lower Fr am e Member s

Except where vertical joist supports are required, upper frame members for

crat es over 54 inches wide shall always be 2 inches t hick and a m inimum of 2

X 4 inches in size. Splicing of upp er or lower fram e member s sha ll be done

over or un der a stru t an d sha ll be as shown in figure 6-64.

Ver t i ca l S t r u t s

Vertical strut s shall be continuous from th e lower frame m ember t o the upp er

frame member and the diagonal and horizontal braces shall be cut in

between. The end stru ts sha ll be as shown in ta ble 6-33.

Hor i zonta l braces

Horizontal braces for Types B and C panels (figures 6-64 and 6-65) shall be

the same thickness as th e struts and 4 inches wide.

Diagonals

Size of diagonals shall be as specified in the member selection tables 6-34 to

6-43 an d sha ll be located as sh own in figures 6-63, 6-64 an d 6-65. When

frame members are 1 inch thick, gusset plates shall be cut from 1/4-inch

plywood and sha ll be 12 inches minimum , in th e shortest dimension. The

corners sh all coincide with th e center line of th e diagona ls as sh own in figur e

6-65.

J o i st S up por t s

The upper frame members shall serve as supports for tops. When cra tes are

6 feet wide and 12 feet high or 8 feet wide and 10 feet high (tables 6-34 to 6-

43) and when the struts are 1 inch thick, vertical joist supports shall be

provided as shown in figur e 6-66. These sh all consist of 2 by 4 inch mem bers

placed on and nailed to the frame members of the side and extending under

each in ter ior joist to th e floor.

Table 6-32. Side panel types - class 1 crat es

Inside height of crate

(in.)

Type of pa nel Refer en ce figu re

No.

Over 24 to 60 A 13

Over 60 to 108 B 14

Over 108 to 144 C 15




6-106

Table 6-33. E nd strut requirement s

Net load (lb.)

Nominal size of end stru ts

Bolted cra te (in .) Nailed cra te (in .)

1,000 or under 2 X 4 2 X 4

Over 1,000 but under 5,000 3 X 3 2 X 4

5,000 and over 4 X 4 2 X 4

Figur e 6-58. Na rr ow tops (width s up t o 54 inches) (MIL-C-104).




6-107

Figur e 6-59. Int erm ediat e tops (width s over 54 inches to 60 inches) (MIL-C-104).




6-108

Figur e 6-60. Wide tops (width s over 60 inches t o 120 inches) (MIL-C-104).




6-109

Figur e 6-61. Fa brication of tops (na rr ow an d inter media te) (MIL-C-104).




6-110

Figur e 6-62. Fa brication of tops (wide t op) (MIL-C-104).




6-111

Figur e 6-63. Sides type A pan el (lum ber) (height s over 24 inches to 60 inches)

(MIL-C-104).




6-112

L iners

A crate liner shall be applied between the sheathing and frame members of

sides and ends of all lumber-sheathed crates and shall conform to the crate

liners specified in PPP -B-1055. The pap er sha ll be placed horizont ally as

un rolled, with a 4-inch minimu m sh ingle lap a pplied for pr oper draina ge and

shall cover th e entire framed ar ea. Vertical joints, when r equire, shall have a

minimum 4-inch lap and shall be located at a vertical member.

S h e a t h i n g

Sheathing for the side and end panels of crates shall be applied vertically,

shall extend t o the bottom of the skids one side panels and to the tops of skids

on the end panels of skid type base crat es. Sheat hing shall extend to the

bottom of sills on sill-type base crates. Sheat hing sh all be eith er t ongue-an d-

groove or squ ar e and sh all be 1 inch th ick. At least one side of all boar ds

shall be dressed and t he dressed side placed out ward. No boar ds shall be less

tha n 4 inches in width. En d boards sh all be not less tha n 6 inches wide and

preferably wider. No more th an 10 percent of the boards (not more tha n one

out of 10 board s) shall be of the minimu m width , nor sha ll the n arr ow boards

be adjacent t o each other . Short boards, not less tha n 2 feet in length, may be

used un der th e following conditions (figure 6-67):

• boards sh all be cut at r ight angles,

• the center of a short sheathing board shall be at the approximate

center of the width of a diagonal an d sh all have full coverage by t he

diagona l, or sha ll be joined on a horizont al mem ber,

• at least every second board and all end boards shall be full length,

and

• nailing shall be as shown in figure 6-67.


Nails securing sheathing to framing up to and including 2 inch thickness

shall be driven th rough th e sheat hing an d shall be of such length as t o permit

a minimum of 1/4-inch clinch on the fra ming. For nailing sheath ing to

horizontal and diagonal frame members 4 to 6 inches wide, three rows of

nails shall be used. There sha ll be a minimum of th ree na ils per crossing in

sheathing boards 4 to 6 inches wide and a minimum of four nails in wider

boar ds (figure 6-67). For na iling sheat hing to horizonta l and diagonal frame

mem bers over 6 inches wide, four rows of na ils sha ll be used. Ther e shall be

a m inimum of four na ils per crossing in sh eath ing boards 4 to 8 inches wide

an d a minimu m of five nails in wider boards (figure 6-65). For na iling

sheat hing to strut s 4 to 6 inches wide, two rows of nails shall be used. The

nails shall be spaced approximat ely 8 inches apa rt in each row and st aggered.

For wider stru ts use three rows of na ils. The nails shall be spaced

appr oximately 12 apart an d staggered. Nail spacing at vertical butt joints

shall be as shown in figure 6-67. Gusset plates sha ll be secur ed withsevenpenny nails driven through and clinched on the sheath ing. Nailing

sha ll be shown in figure 6-66. Vertical joist supp orts sha ll be secur ed with

two tenpenny nails at each horizontal frame member crossing and one

tenpen ny nails at each diagona l crossing as shown in figur e 6-66. Where

vertical joists coincide with struts, there shall be two rows of nails on 30 inch

centers.




6-113

Figure 6-64. Sides type B panel (lumber) (heights over 60 inches to 108 inches)

(MIL-C-104).




6-114

Figure 6-65. Sides type C panel (lumber) (heights over 108 inches to 144 inches)

(MIL-C-104).




6-115

L a g S c r e w R e i n fo r c in g S t r a p fo r B o l t e d C r a t e s

Reinforcing strap shall be used on side and end panels of all demountable

crat es as shown in figures 6-68, 6-69 and 6-70. Galvanized steel stra p,

punched or drilled, 1-1/4 inches by 0.035 inch of 3/4 inch lag screws, and 2

inches by 0.050 inch for 1/2 and 5/8 inch lag screws, shall be nailed to the

inner face of the sheathing between the lower edge of the bottom frame

member an d the bottom of the shea thing as shown in figur e 6-68. The stra pshall be located to coincide with t he center of the skid or header an d sha ll be

nailed on maximum 2 inch centers to the sheathing with clout or similar

na ils. Na ils sha ll be clinched at least 3/8 inch.

E n d s

En d types a nd size of members for en ds in crat es over 30 inches wide sha ll be

determined in a manner similar to the sides, except that in all cases the

thickness of the upper and lower frame members shall be the same as the

stru ts specified in tables 6-34 to 6-43. The member arr angemen t shall

conform, to the details shown in figure 6-81. For crates less tha n 30 inches

wide, single diagonals only are r equired an d all fram e members sh all be 1 by

4 inches in size as sh own in figure 6-81.

ASSEMBLY (CLASS 1 CRATES )

B OLTED CRATE

G e n e r a l

Type II (bolted) crat es sha ll be assembled with la g bolts. Lead h oles sha ll be

used for la g bolts.

F a s t e n i n g S id e s t o B a s e

The sides sha ll be secur ed to th e skids with lag bolts. For 3 X 4 inch skids,

3/8 inch diameter by 3-inch long lag bolts shall be used; for 4 X 4 inch skids,

1/2 inch diamet er by 4 inch long lag bolts sha ll be used. The nu mber of lag

bolts sh all be as specified in ta ble 6-44. One-ha lf th e num ber sha ll be used on

each side an d the spa cing shall be uniform along th e skid. Maximum spa cing

shall be 16 inches for 3/8-inch lag bolts and 20 inches for 1/2 inch lag bolts.

Lead holes shall be drilled in line with and through the center of the metal

reinforcing strap, as well as through the sheathing and into the skid.

Assembly and placement details sha ll be as shown on figur es 6-71 an d 6-72.

Fa s t en i n g S ides t o Top

Lag bolts, 3/8 inch diameter by 3-1/2 inches long, shall be used to fasten the

sides to the t op. These lag bolts shall be placed so tha t th ere is one in th e end

of each joist at th e appr oxima te center (figur e 6-73). For tops without joists,

lag bolts shall be placed at the a pproximat e center of the side frame m ember

of the t op and spaced no great er th an 24 inches apar t.

F a s t e n i n g E n d s t o T o p , S id e s , a n d B a s e

Lag bolts for fastening ends to tops shall be 3/8 inch in diameter by 2-1/2

inches long. Lag bolts for fasten ing ends to sides sha ll be 3/8 inch diam eter

by 3-1/2 inches long. Placement a nd oth er assem bly details sha ll be as sh own

in figure 6-71 an d 6-73. Lag bolts for fasten ing ends to base sha ll be the

sam e size. Locat ion an d spacing shall be as sh own in figures 6-71 and 6-72.

Lead holes shall be centered on the r einforcing stra p.




6-116




6-117




6-118




6-119




6-120




6-121




6-122




6-123




6-124




6-125




6-126

Figur e 6-66. J oist supp orts an d guss ets (MIL-C-104).




6-127

Figur e 6-67. Fa brication nailing of lum ber shea th ing (MIL-C-104).




6-128

Figur e 6-68. Lag screw r einforcing str ap for bolted crat es (MIL-C-104).




6-129

Table 6-44. Lag bolts re quired t o ass emble sides to base of bolted cra tes u sing lag bolt reinforcing

str ap (skids to be Group I I, III, or IV woods).*

Weight of crate and

cont ent s (lb.)

Size of lag bolt

3/8 x 3-inch (3x3 or

3x4 inch skids)

1/2 x 4-inch (4 x 4 inch

skids)

5/8 x 4-inch (4 x 6 inch

skids)

2,000 6 6 6

3,000 10 6 6

4,000 14 8 6

6,000 20 12 8

8,000 ... 16 10

10,000 ... 18 12

12,000 ... 22 14

14,000 ... 26 16

16,000 ... 30 18

18,000 ... 32 22

20,000 ... 36 24

24,000 ... ... 28

28,000 ... ... 3232,000 ... ... 36

36,000 ... ... 42

40,000 ... ... 46

* Use one-half the nu mber on ea ch side:

Maximu m sp acing - 3/8 x 3 - 16 inches on cent er

1/2 x 4 - 20 inches on center

5/8 x 4 - 20 inches on center

Minimum nu mber - 3 per side, 2 per end




6-130

Figure 6-69. En d pan els over 30 inches wide lum ber shea th ed crates (MIL-C-104).




6-131

Figure 6-70. Narr ow end pa nels (lum ber sh eath ed crates) (MIL-C-104).




6-132

Figur e 6-71. Assembly of bolted crat e (lum ber or pylwood sh eat hed ) (MIL-C-104).




6-133

Figu re 6-72. Assem bly of bolted cra te (MIL-C-104).




6-134

F igur e 6-73. Assem bly of bolted crat e (MIL-C-104).




6-135

NAILED CRATE

G e n e r a l

Type I crat es shall be assembled with na ils and m etal stra ps. Genera l rules for

crat e assembly sha ll be as shown in table 6-45 an d figures 6-74 and 6-75.

F a s t e n i n g S i d e s a n d E n d s t o Ba s eSides and ends sh all be na iled to the skids an d hea ders with cement -coated na ils

(figure 6-74). Two rows of nails sha ll be used for 2 by 4 inch, 3 by 3 inch, 3 by 4

inch a nd 4 by 4 inch skids or h eaders a nd for style b bases. The nu mber of nails

required for t he perimet er of th e crate sha ll be as sh own in table 6-46, and ba sed

on the gross load. Nail spacing sha ll be no greater t ha n 6 inches in each row, an d

not less than t wo nails shall be used in each sheat hing board .

F a s t e n i n g E n d s t o S id e s a n d S id e s t o E n d s

The end panels shall be nailed to the side panels with twentypenny cement-

coated nails spaced 12 inches apa rt as sh own in table 6-45 and figure 6-74. The

nails shall pass through the sheathing and the edge struts of the ends into the

edge of the corner str ut s of th e sides. Predr illing sha ll be used for these na ils to

prevent splitting a nd t he bit for dr illing sh all be approximat ely 75 percent of th ediameter of the n ail sha nk. The edge sheat hing board s of the side panels shall be

nailed to the edge str uts of th e ends with eight penn y cement -coated na ils spaced

6 to 8 inches a par t (figure 6-74).

F a s t e n i n g T o p t o Si d e s a n d E n d s

Tops shall be fastened to sides and ends with corner reinforcing straps and

tensioned straps with anchor plates as shown in figure 6-75. Corn er stra ps shall

be of such length as to allow nailing into framing of sides and ends.

S t r a p p i n g

Stra pping sha ll be used a s shown in figure 6-75 on a ll bolted crates with net loads

over 3,000 lb and for all nailed crat es. Tensioned meta l strapping an d corn er

straps shall conform to ASTM D 3953, Type 1 or 3, Zinc-Coated finish, Grade 2,

not less tha n 3/4 inch wide by 0.028 inch thick. Corn er stra pping shall be

prepun ched or drilled. In addition, on crat es with style b bases, corner

reinforcing str aps sh all be applied at t he bottom corn ers a s shown in figure 6-76.

Na ils shall be 1-1/4 to 1-1/2 inch galvan ized roofing na ils. A minim um of th ree

nails shall be used for each strap leg and strapping shall be located so that

nailing is in a frame member .

C LASS 2 C RATES

Class 2 crates shall be Type I or II as specified and shall have the same use

limitat ions as described for lumber-sheath ed.

B a s e s The constr uction of bases sh all conform t o bases of Class 1 crat es.

Tops

The constr uction of tops for Clas s 2 cra tes is ident ical to th at described for Class 1

tops.




6-136

Sides ( see f igur es 6-77 thr u 6-79)

N u m b e r a n d T y p e o f P a n e l s

Types of panels for va rious heights a nd corresponding illust rat ive figure nu mber

shall be as shown in table 6-47.

Type B panels include a h orizontal bra ce an d Type C pan els have two horizonta lbraces. These shall be located so as to equally divide the space between u pper

and lower fram e members. For all types of side panels, strut s shall be spaced 24

inches on centers except at one or both ends so that 48 inch-wide plywood can be

utilized with a minimu m of waste. Sides shall be constru cted as shown in figures

6-80 to 6-81. In crates with Style b bases, the sh eath ing of sides an d ends sh all

reach below the horizontal frame member a distance equal to the depths of the

sills.

Table 6-45. Assembly Na iling of Na iled Crat e (MIL-C-104)1

Fasten Nail size an spacing

Notes

Par t To par t Lumber shea thing Plywood shea thing

Sheathing of

side and end

Skid and end header

(skid base)

Eightpenny minimum

size

3-inch maximum spacing

Sevenpenny minimum

size 3-inch ma ximum

spacing.

See ta ble 6-40 for n umber

of nails required

End a nd side sills

(sill base )

Two rows up t o 4 x 4

skids

Three rows for 4 x 6 skid

(on edge)

Three rows for all sill

bases

Two rows up t o 4 x 4

skids

Three rows for 4 x 6 s kid

(on e dge)

Three rows for all sill

bases

Predr ill holes for t wenty

penny na ils, 75 percent of

shank diameter

Corner str ut

of end

Corner st ru t of s ide Twen t ypenny-p red r ill 12-

inch spacing

Twelvepenny 12 inch

spacing

Sheathing of

side

Cor n er s tr ut of e nd E igh tp en n y m in im u m

size 6- to 8-inch s pacing

Sevenpenny minimum

size 6- to 8-inch s pacing

1For fastening top to sides and ends use str apping.

Table 6-46. Num ber of nails per ea ch 1,000 pound gross load (nailing sheath ing to base around per imeter of nailed crate).*

Type of na il Size of na il

Wood grou p of skid

II III IV

Sinker or cooler 7d

8d or 9d

10d

12d

23

19

18

15

26

21

19

16

19

16

14

12

Corker 7d

8d or 9d

10d

12d

24

17

15

15

26

19

16

16

19

14

12

12*Nails shall not be less tha n 2 per board (lumber sh eath ing) and sh all neither be more tha n 3 inches apart n ot less than 1-1/2

inches apar t .




6-137


The sizes of the upper and lower frame members and struts shall be determined

from tables 6-34 to 6-43, except as other wise specified. Loads referr ed to in th e

tables shall be the inside measu remen ts of the crat e. The member sizes sha ll be

based on Groups II woods. If the exact size of the cra te is not given in th e ta bles,

member sizes for the crate of the nest greater length and width, and smaller

height, shall be used.

U p p e r a n d L ow e r F r a m e M e m b e r s

The requirements for upper and lower frame members shall comply with those

described for lum ber-sheath ed side pan els in an d listed by size in tables 6-34 to 6-

43.

Ver t i ca l S t r u t s

The requirements for struts shall comply with those described for lumber-

sheat her side panels a nd listed by sizes in table 6-34 to 6-43.

Di agona l s

No diagona ls are required for Class 2 crates.

J o is t S u p p o r t s

The joist supports shall comply with those described for class 1 side panels.

L i n e r s

No liners ar e required for Class 2 crates.

S h e a t h i n g

Plywood sheathing shall be 3/8 inch thick for net loads up to 10,000 lb, and 1/2

inch of net loads over 10,000 lb, and shall be applied so that the face grain is

vertical. Fa ce gra in may be horizonta l for cra tes 4 feet or less in height . Vertical

joints in plywood sheathing sha ll be made over th e center of a str ut . Horizont al

joints in plywood sheat hing shall not be permitt ed in Type C panels. All

horizonta l joints sh all be made over t he center of a h orizonta l brace.


Nailing plywood sheath ing to frame m embers of various widths shall be as shown

in figure 6-80. For all fabrication, na ils sha ll be driven th rough th e plywood an d

clinched a minimu m of 1/4 inch. Sta ples may be used to fast en plywood

sheathing to framing members.

Lag-s c r ew R e i n f o r c i ng S t r ap f o r Bo l t ed Cr a t e s

Reinforcing straps shall be used on side and end panels of all bolted crates as

shown in figures 6-77 to 6-79.

E n d s Panel types and sizes of members for ends shall be determined in a manner

similar to the sides, except th at in all cases, the t hickness of the upper and lower

frame members shall be the same as the struts specified in table 6-34 to 6-43.

The member arr an gement sha ll be as shown in figur e 6-81. Fabr ication shall be

as sh own on figur e 6-80.




6-138

Figur e 6-74. Assembly of na iled cra te, lumber or plywood sheat hin g (MIL-C-104).




6-139

Figure 6-75. Corner and top strapping, (lumber or plywood sheathing (MIL-C-104).




6-140

Figur e 6-76. Sill base str app ing (MIL-C-104).




6-141

ASSEMBLY (C LASS 2 C RATES)

Bo l t ed -c r a t e As s em bl y

The assembly of plywood-sheathed nailed crates shall comply with the details

specified for Class 1 crates except for size of nails which shall be as specified in

ta ble 6-45.

R e i n fo r c i n g S t r a p s

The reinforcing straps shall be as specified for Class 1 crates.

T o l e r a n c e s

A tolerance of plus or minus 1/8 inch is allowable on the overall length and width

of individua l complet ed crat e pan els. Out -of-squa re deviation of individua l

panels shall be not more than 3/16 inch (3/8 inch difference in diagonals).


Crate panels shall be clean and free of slivers and protruding fastener points.

Crate panels shall be square and free of cracks, splits, or other damage which

would pr event easy a nd correct a ssembly and adversely affect t he per forma nce of

assembled cra tes.

F i r e R et a r d a n t

When specified, all lumber an d plywood shall be tr eated in a ccorda nce with MIL-

L-19140. Special markings sha ll be used to indicate the lum ber an d plywood

have been treated with non-leachable fire retardant materials.

CR ATE, SLOTTE D ANGLE, STEE L OR ALUMINUM (ASTM D6255)


The slotted a ngle cra te is designed t o permit ra pid fabricat ion of a crate t hr ough

assembly of slotted angle steel or aluminum with nuts, bolts, and lockwashers

and disassembly and reu se of component mat erial.


The following classificat ions h ave been est ablished for th is cra te.

T y p e s

Type I - cra te, slotted an gle, steel or a luminu m, open.

Type II - crate, slotted angle, steel or aluminum, full enclosed or sheathed with

solid ma terial.

Styles

Style A - crate, slotted, a ngle, steel, or aluminu m, without skids or ru bbing str ips.

Style B - crate, slotted angle, steel, with skid blocks or skids with rubbing strips

and provisions for forklift truck handling.




6-142

Figur e 6-77. Sides - type A pan el (plywood) (height s over 24 inches t o 60 inches) (MIL-C-104).




6-143

Figur e 6-78. Sides - type B pa nel (plywood) (heights over 60 in ches to 96 inches) (MIL-C-104).




6-144

Figur e 6-79. Sides - type C pa nel (plywood) (heights over 96 in ches to 144 inches) (MIL-C-104).




6-145

Figur e 6-80. Fa brication na iling plywood shea th ing (MIL-C-104).




6-146

Figur e 6-81. En d pan els plywood shea th ing cra tes (MIL-C-104).




6-147

G r a d e s

Grade 1 - Crate for domestic and oversea shipments intended for outside or

indeterminate storage.

Grade 2 - Crate for domestic and oversea shipments intended for inside or

protected storage.

Us e

These crates a re su itable for:

ο Pa cking lightweight, bulky items, including airframe component s.

ο Oversea and domestic air an d surface shipment s.

ο Packing items requiring rigid blocking and bracing assemblies, such as

support panels, cushioned saddles, solid and slat cradles, specially

designed brackets, yoke pan el assemblies, etc.

ο Adaptat ion of suspen sion systems or sh ock m ounts for shock a bsorption.

ο Packing repairable, returnable items where a desirable light-weight,

reusable container is specified.

M at e r i a l s

S l o t t ed me t a l an g l es

This material comes in either st eel or aluminum . There ar e thr ee different sizes

of slotted metal angles, variations being based on the size of the flanges and the

thickness of the m etal used in fabricating th e angles. The slotted a ngle mater ial

sha ll conform to Specificat ion MIL-S-21041, as a guide for t he selection of slotted

an gle based on size of cra te a nd weigh t of load.

Steel slotted angle material for Grade 1 crates shall have a zinc protective

coating. Steel slotted angle material for Gra de 2 crat es shall be trea ted with a

primer or a phosphatized base and a baked-on synthetic enamel of high grade

comm ercial qua lity. The color sha ll be DOD Gra y, un less oth erwise specified, in

accordance with F ederal Stan dard 595.

The h ole pat ter n for th e 1-1/2-inch by 1-1/2-inch a ngle sh all be of such a design a s

to provide one line of holes or slots in each flan ge. The 1-1/2-inch by 2-1/4-inch

angle shall have one line of holes or slots in the narrow flange and two lines of

holes or slots in the wide flange. The 1-1/2-inch by 3-inch an gle shall ha ve one

line of holes or slots in the narrow flange and three lines of holes or slots in the

wide flan ge. The hole patter n sha ll be of continua l repetition an d shall be

visua lly indexed at 3-inch inter vals.

Occasiona lly, it may be necessar y to splice pieces. When th is occurs, either th e

lap or butt splice may be m ade.

Bo l t s an d N u t s

Bolts and nuts used in joining slotted angle frame members of the crate shall

conform t o Specification MIL-S-21041, except t ha t n ut s sh all conform t o MS51922

with t he exception tha t 5/16 nut s sha ll be .551 to .564 inches a cross th e flats.

Bolts and nuts used in attaching sheathing and wood members of the crate (and

any wood blocking and bracing therein) shall be fastened to a slotted angle

material with not less than two bolts on each panel edge, with additional bolts

being employed, if necessary, to mainta in th e interval between bolts at not m ore




6-148

tha n 12 inches. When sheat hing is att ached to the top by na iling to a wooden

strip wh ich is secured t o the slotted a ngle portion of the cra te by bolts spaced not

less than 24 inches apart, the nailing strip will be at least 1 by 2 inches and the

nails will be at least sixpenny in size, spaced not more than 5 inches apa rt.

Vent i l a t ion

Crates completely enclosed or sheathed with plywood or paper-overlaid veneerwill be ventilat ed. Ventilat ion will be accomplished by mea ns of holes or slots in

the ends or ends and sides around th e perimeter of the crat e. They shall be place

immediately below the tip fra me members of the ends an d sides. When crates

are over 10 feet in length, the ventilation holes or slots will be divided equally

between both ends and both sides and located as near the midpoint of the sides

and ends as pr acticable. Place baffles or sh ields inside the crat e to deflect t he

water blowing into the crate, thus preventing the water from coming in contact

with th e conten ts. The following ta ble establishes th e area of the h oles or slots

required t o provide ventilation for gradu ated ra nge of volume for a crate (table 6-

47).

P a n e l s fo r M a r k i n g O p e n C r a t e s

To provide sufficient area for placing r equired ma rkings on open crates, a pan elof 1/4-inch p lywood will be bolted to t he crat e.

Spec i fi c Cr a t e s

Type 1 , S ty le A

This crate is of simple construction, usually consisting of one panel in each

section, requiring minimum bracing and used for light, bulky, and small items

not exceeding 200 pounds. Eith er the slotted angle aluminu m or the smaller

slotted an gle steel is usu ally str ong enough of th is crat e. Un less specifically

excepted, it is limited t o maximum dimensions of 80 inches in width .

Table 6-47. Vent ilation requir ement s

Area of holes or slots for ventilation

Volum e of crat e in

cubic feet

Cumulative area in squar e

inches of ventilation holes

or slots

0-106............ 7

106-141.......... 10

141-176.......... 13

176-388.......... 27

388-600.......... 33

600-777.......... 54

777-989.......... 66

989-1236......... 81

1236-and over .... 101




6-149

Si des

The met al an gle used for t he side r ails (horizont al mem bers) should be positioned

with th e wider flange par allel to the plan e or su rface of the side. The bottom rail

should be positioned so that the wide flange points up, while the top rail should

have th e wide flange point ing down. Vert ical members (stru ts) should be equal

in length and be positioned so that they are within horizontal rails when the

crat e is assembled. Vertical members should not exceed 48 inches in length a nddistance between vertical members (struts and intermediate struts) shall not

exceed 1-1/3 the height of the crat e. Where greater side strength or special

mounting provisions are required along the side of the crate, extra vertical

members may be added with the wide flange against the wide flange of the

horizont al members (side rails) of th e crate. Additiona l or int ermediat e vertical

members sh ould be added wh ere th e length-to-height r atio dictat es.

E n d s

The crat e ends sha ll consist of slotted an gle crossmembers joining t he t wo crat e

sides. Additiona l crossmember s joining th e two crat e sides. Additional

crossmembers or intermediate struts to provide mounting or attaching points

within th e cra te for specific items may be added to crat e end as r equired. The

distance between the lateral members (crossmembers and intermediate struts)shall not exceed 1/1/3 the width of the crate.

B a s e

The base is not a separate panel which is bolted to the sides and ends, but is

formed by the addition, as necessary, of crossmembers, (loadbearing members,

floorin g, an d br aces).

Fl oo r i ng

The crat e will be sufficient ly floored to protect the conta ined item . The flooring

need not be continuous throughout the base; however, it will be placed in such

locations that will provide protection to the areas of the contained item that are

subject to damage by forklift trucks or other material handling equipment.

Plywood flooring (except loadbearing floorboards) will be a minimum of 1/4 inch

thick for crates through 12 inches wide 3/8, inch for crates over 12 inches wide

and through 24 inches wide, and 3/4 inch thick for crates over 24 inches wide.

Flooring will be cut to fit snugly in place and securely bolted to the lower side

ra ils of th e cra te. Ea ch piece of floorin g shall be bolted in place with a m inimu m

of two bolts in each lower side ra il. The dista nce between bolts used to secur e the

floorin g sha ll not exceed 12 inches. When t he flooring is 3/8 inch or less in

thickness it is reinforced on top by an additional strip of wood 1 X 2, through

which th e holddown bolt will pas s. Bolts u sed of securin g floorboards sh all not be

less than 5/16 inch in diam eter.

L o a d b e a r i n g M e m b e r s

Loadbearing members shall be located within the crate base to carry the load of the contained item, except when suspensions systems are used or when the item

is attached to the side structur e. The size of wood members sh all be determ ined

from table 6-48. The size of steel mem bers sh all be deter min ed from ta ble 6-49.

C r o s s m e m b e r s

Crossmembers will be of the same strength and quality as the slotted angle used

of the side rails and st rut s. Crossmembers in the base will be spaced not more

tha n 24 inches apar t. If loadbear ing members are employed, they should be

included in t he considerat ions for base crossmembers.




6-150

B r a c e s

The base should be reinforced with braces of the same slotted angle as the

crossmembers. These braces should be used in unfloored areas of the crat e.

When one-third of the base is floored with 12-inch or wider floor panels, braces

are n ot r equired.

C r a t e T o pThe top, like the base, is not a separate panel which is attached to the sides and

ends. It is formed by crossmembers, crossties members, and braces inst alled

between the two cra te sides. The crossmembers ar e placed perpendicular to the

sides and ar e placed at each point where a vertical stru t is bolted t o the side rail,

being bolted as sh own in figur e 6-82. Altern ate m ethods of att aching members

are shown in figur e 6-83. The crosstie members ar e slotted angle members

placed at intermediate points between, and parallel to, crossmembers with the

distance between t he crossmembers an d crossties not exceeding 1-1/3 th e width of

the crate. Braces of the sam e type slotted an gle ma terial as that u sed for

crossmembers are placed diagonally in t he r ectan gle form ed by the side rails an d

the crossmembers an d crossties. The ends will be cut a t an a ngle to give

maximum contact of the flanges being bolted t ogether .

Figure 6-82. Joining of Intermediate members (ASTM D6255).




6-151

Table 6-48. Allowable Load per in ch of floorboard widt h for Group s II, III a nd IV woods

Distance between

outside skids

Actual thickness of floorboards (inches)

3/4 1-1/2 2-1/2 3-1/2

(inches) (pounds) (pounds) (pounds) (pounds)

12 48 220 574 1,095

18 32 147 382 731

24 24 110 287 548

30 19 88 229 438

36 16 73 192 365

42 14 63 164 313

46 12 55 144 274

59 9 44 115 219

72 8 37 96 182

If groups III or IV woods are u sed, the a bove allowable loads m ay be increases 20 per cent.

Table 6-49. Load capa city of slotted an gle steel beams. 1/

SLOTTED ANGLE STE EL - 2.6mm - 38mm X 76mm

(12 GUAGE (0.014") - 1-1/2" x 3")

(Length of beam in cm (feet) - load in kg (pounds))

60(2) 90(3) 120(4) 150(5) 180(6)

Recommended

load

659(1450) 445(980) 336(740) 227(500) 150(350)

Recommended

load

2045(4500) 1409(3100) 954(2100) 545(1200) 454(1000)

Recommended

load

4727(10400) 3409(7500) 2409(5300) 1977(4350) 1590(3500)

Recommended

load

704(1550) 454(1000) 345(760) 263(580) 222(490)


(14 GUAGE (0.074") - 2-1/2" x 2-1/4")

(Length of beam in cm (feet) - load in k g (poun ds))

60(2) 90(3) 120(4) 150(5) 180(6)

Recommended

load

572(1260) 386(850) 277(610) 181(400) 90(200)

Recommendedload 1090(2400) 772(1700) 522(1150) 372(820) 284(625)

Recommended

load

2359(5190) 1522(3350) 1227(2700) 954(2100) 772(1700)

Recommended

load

363(800) 231(510) 177(390) 136(300) 113(250)

1/ Table 49 is usable for slotted angle steel with flange dimensions that are plus or minus 3mm (1/8 inch) the

flange sizes sta ted.




6-152

Table 6-49a. Load capa city of slotted an gle steel beams. 1/


(14 GUAGE (0.074") - 1-1/2" x 1-1/2")


90(3) 120(4) 150(5) 180(6)

Recommended load 225(495) 122(270) 86(190) 65(145)



1/ Table 49a is usable for slotted angle steel with flange dimensions that are plus or minus 3mm (1/8 inch) the


Table 6-49b. Load capa city of slotted an gle steel beams. 1/


(14 GUAGE (0.074") - 1-1/2" x 1-1/2")

(Length of colum n in cm (feet) - load in kg (pounds))

90(3) 120(4) 150(5) 180(6)




1/ Table 49b is usable for slotted angle steel with flange dimensions that are plus or minus 3mm (1/8 inch) the


Table 6-49c. Load capa city of slotte d angle steel colum ns. 1/(Contin ued)


(14 GUAGE (0.074") - 1-1/2" x 2-1/4")


90(3) 120(4) 150(5) 180(6) 210(7)

Recommended load 1131(2490) 840(1850) 695(1530) 581(1280) 427(940)






6-153


(12 GUAGE (0.104") - 1-1/2" x 3")


90(3) 120(4) 150(5) 180(6) 210(7)



Recommended load 4045(8900) 3609(7940) 3045 (6700) 2636(5800) 2113(4650)

1/ Table 6-49c is usable for slotted angle steel with flange dimensions that are plus or minus 3mm (1/8 inch)

the flange sizes stated.

TABLE 6-49d. Load capa city of slotted angle alum inum configura tions. 1/


(13 GUAGE (0.089") - 1-1/2" x 2-1/4")


90(3) 120(4) 150(5) 180(6)


Recommended load 431(950) 272(600) 2/181(400) 2/159(350)



(13 GUAGE (0.089") - 1-1/2" x 2-1/4")


90(3) 120(4) 150(5) 180(6) 210(7)




1/ Table 6-49d is usable for slotted angle aluminum with flange dimensions that are plus or minus 3mm (1/8

inch) the flan ge sizes sta ted.

2/ On spa ns of th is length, cross bracing gives a better str uctur e, higher r ecommended load.

Us e o f Cor n e r Br aces fo r L i gh t Cr a t e s

Where crates a re inten ded for n et loads not in excess of 200 poun ds an d limited to

the maximum dimensions of 60 inches in length, 30 inches in width, and 48

inches in height, corner bracing may be utilized in lieu of full diagonal bracing.

Type I I , S ty le A Cra te

This crat e is ident ical to the Type I, Style A crat e, except t ha t it is fully closed or

sheathed using plywood, paper-overlaid veneer, or fiberboard, as specified above.

Sheat hing should be added.

Type I , S t y le B Cr a t e

The Style B (skidded) crate is intended for use in crating larger and/or heavier

items, employing a skidded base; braced sides, ends and top; loadbearing and

att aching members; an d provisions for truck and cargo sling han dling. Only

slotted angle steel (not aluminum) will be used in fabricating this style crate.




6-154

Unless specific approval is given for a larger size crat e, th e ma ximum dimensions

ar e 360 inches in heigh t (see figur e 6-86 for a typical cra te).

Si des

Crate sides consist of horizontal members (side rails), vertical members (struts),

and full diagonal bra ces.

Figur e 6-83. Alter na te meth ods of at ta ching members (ASTM D6255).




6-155

Figur e 6-84. Meth ods of shea th ing or covering cra tes (ASTM D6255).




6-156

I n t e r m e d i a t e H o r i zo n t a l Me m b e r s

When a crate exceeds 48 inches in height, and intermediate horizontal member

should be placed between the top and bottom side rails and should run the full

length of th e crat e. In addition to the requ irement for additional inter mediate

horizontal members because of the height, extra strength requirements may

deman d additional horizontal members.

I n t e r m e d i a t e Ve r t i c a l St r u t s

Intermediate struts shall be evenly and systematically spaced throughout the

length of the crat e side between the en d or corner vertical strut s. The spacing of

intermediate struts for crates with sides not provided with an intermediate

horizonta l member sha ll be determ ined by the height an d length . The distance

between the vertical struts sh all not exceed 1-1/4 the h eight of th e cra te. The

spacing of intermediate struts for crates with sides provided with intermediate

horizonta l member shall be determined by the sa me meth od as above, except th at

the height shall be considered as the distance between the two adjacent

horizonta l members.

E n d s

The ends are not assembled panels which are bolted to the sides but are formedby the upper and lower crossmembers, intermediate crossmembers, and braces

which join the sides. In addition to the upper a nd lower crossmembers,

intermediate crossmembers are required when the height of the crate exceeds 48

inches or when the h eight of the cra te exceeds 1-1/4 width of th e cra te. The

maximum interval between any two adjacent crossmembers is 48 inches.

Intermediate crossmembers shall be installed with the wider flange of the angle

in a vertical position. Int ermediat e vertical members ma y be added to the ends

for special mount ings and special blocking an d bracing. Bra cing of th e ends may

be done either with slotted an gle materials equal t o that used for side bra cing or

with flat st eel stra pping (as above). When a cra te is in excess of 60 inches long,

18 inches wide, or subject to being pushed by forklifts or other equipment, it

should be equipped with push plates to protect the crate and contents (figure 6-

87). The push plat es are positioned across the lower par t of the en d pan el with

the lower par t of plate flush with top of th e skids an d sha ll be bolted to th e corn er

stru ts with a m inimum of two bolts in each end of the plat e. Group II, III, or IV

wood or plywood may be used for crates having a gross weight up to 500 pounds.

They shall be Group III or IV wood when the gross weight exceeds 500 pounds.

When push plates are made from wood they shall be a minimum 1-5/8 inches

thick and 7-1/2 inches wide. Plywood push plates sh all be a minimum 3/4 inch

thick and 12 inches wide.

Top

The top, like the ends, if formed by joining the two sides together, through the

use of crossmember s, crossties, an d braces of slotted angle mat eria l. The end

crossmembers serve also as the top crossmembers of th e ends. Additiona lcrossmembers a re bolted as sh own in figur e 6-84, the wider flan ge being vertical

and t he na rrow flange at he top. Figure 6-84 and 6-85 show methods which ma y

be used in sheat hing or covering cra tes. When the distance between the

crossmembers is greater than 1-1/4 times the width of the crate, intermediate

crossmembers (crossties) should be used, pacing them equidistant between the

crossmembers. Sufficient crossties should be used to maint ain a n inter val not in

excess of 1-1/4 times the width of the crate between any two adjacent

crossmembers and/or crossties. Fu ll diagonal braces should be used in th e

interval between a djacent crossmembers an d/or crossties. Tension bra ces of steel

stra pping may be u sed in lieu of slotted an gle material.




6-157

B a s e

Crossmembers and crossties tying the side panels together at the bottom of the

crat e plus r equired loadbearing mem bers, forklift h an dling members, skid blocks,

full skids, headers, and flooring comprise the base.

Sk i d B l ocks an d Fu l l Sk i dsWhen th e load cont ained by th e cra te exceeds 500 poun ds, full skids run ning th e

length of the crate sha ll be used. Fu ll length skids may be used for lesser

contained weights, but ar e not mandat ory. Fu ll length skids shall be fabricated

from minimu m n omina l 2 X 4 inch lumber for n et loads up t o 1,000 poun ds an d 4

X 4 inch lumber for net loads exceeding 1,000 poun ds. They sha ll be provided

with 2 X 4 inch ru bbing strips. When full length skids ar e not used, 2 X 4 inch

skid blocks 16 inches long ar e used. Skids an d skid blocks shall be beveled 45

degrees on each end. Skid blocks located a t th e ends of the crat e shall be set 2-

1/2 to 4 inches from each crat e end to permit th e use of slings. Rubbin g strips on

full length skids shall be set back an equal distance from each crate end.

Intermediate skid blocks shall be placed in locations that will support loads

tra nsferred to th e lower side rails by loadbear ing members an d strut s. The

center of balance of the loaded crate shall be the determining factor in locatinginterm ediate skid blocks to provide the forklift entr y. The maximu m distan ce

between sk id blocks sha ll not exceed 48 inches. Skid blocks, skids, an d ru bbing

strips shall be bolted to the lower side rails with minimum 5/16 inch diameter

bolts.

L o a d b e a r i n g M e m b e r s

To provide direct support to loads resting on the base, loadbearing members are

used. These members may be either wood, plywood, metal, or a combination of

wood and m etal ar e placed at right a ngles to the length of the crate, being bolted

to both of the lower side members. See tables 6-47 and 6-48 for tabulat ed dat a t o

be used in determ ining the size, etc., of mat erial for loadbearing m embers.

Fl oo r i ng

Flooring may be lumber or plywood and need not be continuous throughout the

base; however, it shall be placed in such locations as will provide protection to the

areas of the contained item that is subject to damage by forklift trucks or other

mat erial han dling equipment . The flooring should be cut t o fit snu gly in place

and should be bolted to both of the lower side each end of each piece of flooring

with a min imum of two bolts to a ra il. Plywood floorin g shall have a m inimu m

th ickn ess of 3/8 inch for cra tes t hr ough 12 inches wide, 1/2 inch for cra tes 12 t o 24

inches wide, an d 3/4 inch for crat es over 24 inches wide. Lum ber floorin g shall

have a minimum thickness of 3/4 inch.

F o r k l i ft H a n d l i n g M e m b e r s

Forklift handling members of lumber of metal, the side of which is based onstrength required as applied to the data shown in tables 6-47 and 6-48, will be

placed 24 inches from each end of the crate and at right angles to the length,

being bolted to both of th e lower side ra ils. When t he crat e is in excess of 36

inches in width, forklift handling members should be placed at the location

provided for side entry of forklifts and, if the crate is over 8 feet in length, they

should be in addition to th ose placed 24 inches form the end. Loadbear ing

members, if suitably located, may serve as forklift h an dling members.




6-158

Type I I , S t y le B Cr a t e

Except for th e sheath ing, this crat e is fabricated in th e same ma nn er as t he Type

I, Style B cra te. The sheat hing is accomplished in th e man ner described above.

C r o s s t ie s a n d H e a d e r s

When the distance between loadbearing members exceeds the width of the crate

and the flooring is less than 3/4 inch thick, intermediate crossties should beinst alled, being bolted t o both of th e flanges of both lower side ra ils (figur e 6-82).

Figur e 6-85. Meth ods of at ta ching sheat hin g (ASTM D6255).




6-159

Figur e 6-86. Type I, style B crat e (ASTM D6255).

Figure 6-87. Method of atta ching pu sh plat es, skids, an d hea ders (ASTM D6255).




7-1

Chapter 7

CONSOLIDATION AND UNITIZATION FOR

SHIPMENT AND USE OF CARGO CONTAINERS

CONSOLIDATION AND UNITIZATION FOR SHIP MENTConsolidation is the bringing together of like or unlike items for shipment.

Once the items are assembled, they must be kept together as a single unit

un til th ey reach a break-bulk point or the ultimate consignee. Unitization

results in economy through reduction in handling and documentation, one

un it tak ing the place of several un its.

ADVANTAGES

Figur e 7-1 gives advan ta ges of un itizing loads wh ich a re a follows:

• Eliminates laborious and expensive manual handling of individualitems.

• Reduces dama ge to items by eliminating ma nu al han dling.

• Perm its savings in h and ling costs.

• Reduces personnel accidents by eliminating manual handling and

lifting.

• Simplifies inventorying and reduces inaccuracies.

• Utilizes storage heights n ot possible by man ua l means.

Figur e 7-1. Advant ages of cargo un itization.




7-2

• Reduces pilferage because of unitization of items by steel straps and

other bonding methods.

• Perm its faster movement of supplies an d equipment . Reduces

mar king requirement s on individua l containers.

METHODS OF UNITIZATION

The t wo basic form s of un itization a re--

• Palletization . Palletization is the placing of a number of packages on

a low, portable platform constructed of wood, metal, or fiberboard, or

a combina tion of these m ater ials.

• Conta inerization. Conta inerization is th e placment of a nu mber of

packages into a intermodal container, which not only reduces the

number of units and documentation, but provides additional

protection to th e packages.

P ALLETIZING UN IT LO ADS (MIL-HD BK-774)MIL-HDBK-774 gives the palletized unit load requirements for Department

of Defense mat erial using th e pallets discussed in Chapter 3. The stan dar d

establishes loading patterns for various types of commodities, listing the

patt ern for stacking containers a nd t he met hods of unitizing to be used.

TYPE S OF P ALLETS

• NN -P-71. Types I (2-way entr y), an d III of NN -P-71 are int end ed for

use in stora ge oper at ions. Types IV an d V of NN -P-71 ar e for use in

storage and shipment worldwide regardless of mode of

transportation.

• MIL-P-15011. Type I (4-way entr y) of MIL-P-15011 should be used

for the palletization of military supplies whenever 4-way entry is

required in the storage and distribution system and in support of

NATO forces. Nonst an da rd 4-way ent ry 40- by 48-inch pallets sh ould

be reused for the storage and shipment of materiel to CONUScons ignee s. (fig 7-2)

Li m i t a t i ons

The following size and weight limitations apply to the complete load

including th e pallet an d th e bonding and storage aids (fig 7-3).

Unless otherwise specified by the procuring activity, load units prepared for

shipment in MILVANs and SEAVANs shall not exceed 40 inches in length.

All other loads shall not exceed 43 inches in length, which permits an

overhang of 1 1/2 inches at each end of the pallet.

Unless otherwise specified by the procuring activity, load units prepared for

shipment in MILVANs and SEAVANs shall not exceed 48 inches in width.All other loads shall not exceed 52 inches in width, which permits an

overhang of 2 inches at each side of the pallet.




7-3

Figur e 7-2. Types of pallets .

Load units prepared for shipment in containerization media such as

SEAVANs, etc. shall not exceed 43 inches in height and in MILVANs, 41

inches. All other loads sha ll not exceed 54 inches in height , except as

permitted for loads of compressed gases in cylinders.

The ma ximum gross weight of a load sha ll not exceed 3,000 poun ds per single

pallet load for domestic, intercoastal, or overseas shipments.

TYPE S OF P ALLETIZED LOADS

Types of supplies that can be palletized are--

• Items wh ich a re identical and identified by the sam e stock nu mber.

• Items uneconomical or impractical to pack.

• Rugged and dur able items th at r equire minimum physical protection.

• Boxed items un iform in size requiring a dditiona l protection.

• Items that are moved in large quantities.




7-4

Figur e 7-3. Pa llet size limitat ions.

LOAD ARRANGEMENT

The arrangement of items to the pallet must provide a rigid, compact, uniform

size load, strongly secured to prevent shifting, and capable of resisting impact,

vibration, racking, and compression encountered during handling, storage, and

shipment . Basic principles for a rr an ging and securing loads to pallets are--

• Items should be inter locked, nested, or bun dled whenever possible.

• The load patt ern should eliminat e or reduce void space.• Wood separators or spacers are placed in voids between rows and layers

of irregular-shaped item s to insure a firm a nd st able load.

The top surface of the loading pallet must be level, or made level for stacking

pur poses. This can be accomplish ed by app lying a wood top fra me or leveling

boar ds with a sup porting fra mework.

Loads difficult to stabilize or which are compressible and not sufficiently firm to

support superimposed loads, will be reinforced with a su pporting framework.




7-5

Boxed items are arranged on the pallet so that the markings on individual

cont ain ers do not show on two adja cent sides of th e palletized load. This will

provide clear ar eas for u nit load ma rking.

The load is secured to th e pallet, using ASTM D 3950 requirement s for a pplying

lengthwise an d crosswise stra pping. Horizont al stra pping is the width and

th ickn ess size as th e tie-down str ap size. The gross weight of th e load, divided by

the total number of tie-down straps to be used, determines the weight whichmust be born e by each strap . Non-metallic stra pping is not auth orized for the

str ap ping of palletized loads of wooden , plywood, or m eta l shipping conta iner s.

Strapping is applied in a manner that will eliminate any possibility of slippage.

Wood cleats, tie blocks, or br aces are u sed un der st ra ps when necessary to insure

stability or to bridge un supported spa ns.

L o a d i n g

To properly load a pallet, consideration must be given to the type of item, its

weight, and destin at ion. It is recommend ed tha t MIL-HDBK-774 be followed

when loadin g 40- by 48-inch pallets . Figur e 7-4 shows one type of palletized load

illustrated in the sta ndard.

Figur e 7-4. Exa mples of palletized load.




7-6

SHR INK FILM AND STRE TCH FILM P ALLETIZATION

SH R I N K F ILM

Plastic films such as polyethylene are now being used in accordance with the

requ iremen ts of MIL-HDBK-774 as a mean s of bonding palletized loads. The

plastic film is stretched in the manufacturing process; this is called "orientation".

The str etched film sh rinks wh en subjected to a cont rolled flow of heat air. The

heated air is supplied by the use of a heat shrink cannon or a shrink film

chamber (fig 7-5). The heat causes the film to shrink, conforming to the contour of

the load. For th is reason, it can be used for pa llet loads containing a variety of

items which form irregular shap ed configura tions tha t could n ot be palletized by

conventiona l means. The tightly adhering film immobilizes the contents a nd

provides stability. It also provides some weath er protection for exposed car go.

Shrink film palletization provides a reduction of labor and material cost by the

use of automatic equipment and eliminates the problem of damage caused by

stra pping containers t oo tight.

S t r e t c h F i lm

Stretch films can be used as a means of bonding palletized loads for many

commodities shipped in th e Contin enta l United Sta tes (CONUS) or when sh ippedcont ain erized. The str etch films ar e polyethylene (PE ), polyvinyl chloride (PVC)

or ethyl vinyl acetat e (EVA). The film is wrapped a round t he load in mu ltiple

layers from t he t op of the bottom deckboard to not less tha n t wo inches above the

height of the load. The required th ickness of the wra p is determined by the kind

of film being used a nd t he weight of the load. Additional bonding str ength can be

provided by placing a sh eet of weath er-resistant fiberboar d, the sa me size as t he

top dimensions of the load, on top of the load prior to stretch wrapping.

CONSOLIDATION CONTAINER S (GENER AL)Consolidation containers may be constructed of fiberboard, paper-overlaid veneer,

plywood, or lumber . They ma y be demounta ble or non-demoun table. They are

usua lly secured t o a pallet base or a skid base for handling purposes. Some

containers are intended to be expendable, while others are intended to bereusa ble. Some consolidation conta iners ar e designed t o be compatible with th e

requiremen ts of th e 463L Materials H an dling System of the Air F orce. Others a re

designed t o be used as insert s in tr ansport ers such a s MILVANs, SEAVANs, or to

be used as separa te shipping containers.

BOXES , SH IP P ING INSE RT CON SOLIDATION, MIL-B-43666 (GENE RAL)


These boxes are constructed of wood cleated plywood, plywood wirebound,

double-wall fiberboar d, or tr iple-wall fiberboar d. They are moun ted on pallet-

type bases for ea se of ha ndling. Their constr uction va ries widely depending u pon

the ma terials used. The sizes are such tha t they are modular in concept.

G e n e r a l U se

These boxes are intended for use as inserts in cargo transporters such as

MILVANs, SEAVANs, or as sepa ra te exter ior cont aine rs. They ar e to be used for

Level A or B shipments.




7-7


Ther e are th ree types of consolidat ion inser t cont ain ers. Type I is of wood cleated

plywood const ru ction and has two styles depending u pon th e style of pallet base

used . Type II is of plywood wireboun d constr uction of th e pallet base. Type III is

const ru cted of double-wall or tr iple-wall fiberboar d. Type III has four st yles

depending u pon th e const ruction featu res of the box.

M a r k i n g The marking for shipment will be in accordance with MIL-STD-129.

Figure 7-5. Shr ink film cha mber u sed for heat shrin king film ar ound palletized load.




7-8

TYPE I , WOOD CLEATED PLYWOOD CONSOLIDATION INSERT BOX

(MIL-B-43666)


These containers are wood cleated plywood boxes similar in construction to the

PP P-B-601 cleat ed plywood boxes. They are pr ovided with a four-way entr y

pallet base (fig 7-6).

USE

These boxes may carry Type 1, 2, or 3 loads not exceeding a density of 37 pounds

per cubic foot. Loads exceeding this den sity requir e additiona l box reinforcemen t.

They may be used for domestic an d overseas shipment s. They are inten ded for

consolidation of like and u nlike stock nu mbered items. These cont ainers m ay be

used as inserts in SEAVANs or MILVANs

S IZE AND WE I G H T L IMITATIONS

There are 15 sizes available in the wood cleated plywood consolidation insert

conta iners. The outside length ran ges from 29 to 86 inches. The outside width

ra nges from 31 3/4 to 45 inches. The outside h eight ra nges from 20 to 52 1/2

inches. For MILVAN shipments, the overall height sha ll be not more th an 41inches. The weight capacity for the various sizes ran ges from 1,000 to 2,600

pounds. Table I and II of MIL-B-43666 specifies the length, width, height, and

weight combinat ions for each of the 15 s izes.

C LOSURE

Nail the t op to the top cleats of the sides and ends u sing sixpenn y cement -coated,

chemically etched, or m echa nically deformed na ils spaced thr ee inches a par t. Do

not drive the na ils into the en d gra in of th e vertical cleats.

ST R A P P I N G R EQUIREMENTS

Each vertical corner shall be reinforced with two 8-inch pieces of 3/4-inch flat

steel strapping 0.023 inches thick. The stra pping will be att ached to the cleats

with pneumatically driven galvanized staples 7/16 inches long or with 1-inch longnails pneum atically driven. As an a lterna te, 3/4-inch wide flat, na il-on st ra pping,

0.025 or 0.028-inch in thicknes s, ma y be used . This stra pping, which is

perforat ed with holes spaced 1/2 to 1 3/4 inches apa rt, m ay be secured with lar ge

headed galvanized roofing nails, zinc coated steel roofing nails, or 1-inch

mechanically driven nails. Each stra p will be secur ed with four fastener s. Two

will be driven into th e th rough cleat on th e end of th e box and t wo will be driven

into th e filler cleat on th e side of th e box.

• On boxes 41 inches high, strapping will be placed 13 to 26 inches from the

top of the box.

• One boxes 20 inches high, strapping will be placed 2 and 15 inches from

th e top of th e box.

• On box sizes 5 and 10, which are 43 inches wide, an a dditiona l stra p sh all

be placed to the center of each corner formed by the bottom and end

panels.




7-9

Figu re 7-6. Type I, Style I, wood cleat ed plywood cons olidat ion box (MIL-B-43666).




7-10

Figur e 7-7. Type II, plywood wireboun d consolidat ion boxes (MIL-B-43666).




7-11

TYP E II , P LYWOOD WIREBOUND CONSOLIDATION INSERT BOX

(MIL-B-43666)


The body and top of these boxes are constructed of plywood panels bound together with

bindin g wires. The bottom pan el is fabr icat ed from 1/2-inch plywood which is secur ed to

eith er a skid bas e or a pa llet base (fig 7-7).

USE

The use of Type II plywood wirebound boxes is the same as Type I wood cleated

plywood boxes.

C LASSIFICATION

There are two styles of boxes available under the Type II classification:

• Style 1 box utilizes a double-wing, block-type p allet base (fig 7-6).

• Style 2 box utilizes a skid base having three lengthwise skids which are

cut out to facilitate side entry by forklift trucks.

Si ze an d Weigh t L i m i t a t i ons There are several sizes available in the plywood wirebound consolidation

conta iners. The ran ge of outside dimensions and weight limitations ar e the sam e

as t hose specified for th e Type I, cleated plywood boxes. Tables I, an d II, of MIL-

B-43666 specify the length, width, and height combinations for each of the sizes.

C LOSURE

After the box body is assembled by securing the wire loops with a sallee closure

hand tool, or similar suitable alternate tool, and nailed to the base, make the

closur e by nailing th e plywood top to the t op cleats with t hr eepenny n ails. Space

the n ails 4 1/2 inches apa rt. Complete the closure by applying length wise and

girthwise straps.


Requirements for t he size, nu mber, an d location of straps var y for each style and

size of Type II conta iner s. Consult t he Append ix of MIL-B-43666 for deta iled

requirements for reinforcing the particular plywood wirebound container being

used.

TYP E II I , FIBE RBO ARD CONSO LIDATION INS ER T BOX (MIL-B-43666)

Des c r i p t i on

These boxes ar e made of double-wall or triple-wall fiberboard . The box design

an d constr uction differs for each of th e four designa ted styles. Un less oth erwise

specified, they are furn ished with a pallet base.

USE

Type III fiberboard insert boxes should be restricted to MILVAN, or SEAVAN

when used for level A overseas shipmen ts. They may be used as shipping

containers for Level B overseas shipments and as domestic consolidation

container s. Style 3 should be used for items of assorted stock nu mbers t o be

loaded at origin as inserts only for shipment in MILVAN, and SEAVAN to a

single consign ee ad dres s code. Style 5 should be used for un it




7-12

loads of nonperishable subsistence as required by MIL-L-35078 and sized (in

height) depending on th e ant icipated height of the conten ts.

C LASSIFICATION

Ther e ar e four styles of boxes available un der Type II I classificat ion:

• Style 3, regular slotted box (RSC), is the same as the alternate

construction of the Style E ASTM D5168 fiberboard box with a 1 1/2-inchoverlap of th e out er flaps (fig 7-8). The box ma y be fur nish ed with or

without a pallet base. When a pallet base is used, it ma y be either a

double-wing block-type or double-wing notched runner-type.

• Style 4 half slotted container (HSC) with telescoping sleeve and cap,

consists of a half slotted container bottom section without top flaps, a

sleeve (with stiffening flaps) which fits over the bottom section, and a top

cap which extends down six inches over th e sleeve (fig 7-8). The

requiremen ts for th e pallet base are the sa me as for Style 1.

Style 5 flanged bottom tube with cap, pad, and pallet, consists of a fiberboard

tube with 4-inch bottom flanges, a bottom pad, a nd a t op cap which fits d own over

the body tube (fig 7-8). This type is fur nished with a st ringer t ype pallet base.

Style 6, half slotted container (HSC) with cap and pallet base, consists of a body

having a regular slotted bottom an d a flanged top, and a top cap (fig 7-9). Unless

otherwise specified, it is furnished with a pallet base.

Figur e 7-8. Type III, styles 3 and 4, fiberboar d consolidat ion boxes

(MIL-B-43666).




7-13

S IZE AND WE I G H T L IMITATIONS

There are several sizes available in the fiberboard consolidation containers,

depending upon the styles. The outside length ran ges from 29 to 86 inches. The

outside width ran ges from 31 3/4 to 42 inches. The outside height ra nges for 20

to 52 1/8 inches. The weight limit ra nges from 1,500 to 2,600 poun ds. Style 3 is

available in sizes 1 through 10; Style 4 is available in sizes 23 and 24; Style 5 is

available in sizes 16, 17, 18, and 24; and Style 6 is available in sizes 14 and 15.

Tables I and II of MIL-B-43666 must be consulted for the various length, width,height , an d weight combin at ions of each of th e sizes specified for Type II I boxes.

C LOSURE

The closur e requ irem ent s var y for each style of box. Type III boxes are

constructed in accordance with Specifications ASTM D5168 and MIL-B-43666.

The boxes are closed in accordance with the Appendix of the applicable

specification.


Either metal or nonmetallic strapping may be used to reinforce Type III boxes.

Requirements for t he size, nu mber, an d location of straps var y for each style and

size of box. Consult t he Append ix of MIL-B-43666 for the det ailed requ iremen ts

for reinforcing the particular style and size of fiberboard consolidation box being

used.

P ACKING CONSOLIDATION CONTAINER

P ROBLEMS INVOLVED IN C ONSOLIDATION

The main problem involved in consolidation of materials becomes one of shock

mitigation. The packer mu st be skilled in placing packages in the conta iner so

tha t each pa ckage "wedges in" oth er packages. The packer m ust be able to block

or brace the load as he progresses, in a minimum of time and with the cheapest

and lightest ma terial, yet strong enough to do the job. Essent ially, the problem

becomes one of converting a type 3 load to a type 2 load for protection againstshock a nd vibrat ion.

SHOCK M ITIGATION

In order to meet the problem of shock mitigation relative to consolidation

containers, there are certain basic procedures to follow:

• Try to maint ain level layers.

• Fill all inter na l voids as t he load progresses.

• Keep the center of gravity low an d centered by placing heavy items in the

bottom portion of the container and centering them in the container as

much as possible.

• Block and bra ce the int erior load adequat ely to prevent movement caused

by shock a nd vibrat ion.

B LOCKING AND BRACING THE LOAD

The ideal conditions for full utilization of consolidation containers is to tailor a

container t o the size of un iform interior packages. Of course, th e required

consolidation containers a re genera lly of standa rd dimen sion a nd a re n ot related

to product package sizes.

These ideal conditions a re n ot always present at the depot or base level, but with

a variety of package sizes to place in consolidation containers most of the

available space can be ut ilized in some instan ces.




7-14

Voids tha t occur at t he top of th e pack are pr obably th e most usu al (fig 7-10). In

order to provide holddown media for the load, first cover the packs with pad(s)

and th en place cells between the pads and t he conta iner cover. The use of

adh esives will hold the cells between th e pads an d th e container cover. Cells

should be locat ed wher e stra pping will be placed. Wher e feasible, the corn ers of

the container may be split down to the top of the load and the excess portion of

each side panel, above the top of th e load, ma y be folded in, th us eliminat ing th e

need for cells.

Voids tha t occur a t t he sides of th e pack can be blocked with pa ds an d cells, the

sam e as top blocking a nd bra cing (fig 7-11).

Interior voids (fig 7-12) are the hardest to cope with and the most time-

consu min g. All voids th at would per mit sh ifting of th e packages should be filled

with cells or foamed-in-place materials as t he layers pr ogress. If the packages

ar e un iform, one sleeve may fill th e void for sever al layer s or packa ges.

Compound voids (top and side, two sides, etc. may take a little more skill, but

pads a nd cells can be u sed to block and br ace the sa me as previously discussed.

P ACKING SEMI-P ERISHABLE SUBSISTENCE ITE MSUnit loads of semi-perishable items sh all be prepa red in conforma nce with MIL-

L-35078, Loads, Unit: Prepa rat ion of Semi-perishable Subsistence Items:

Clothing, Personal Equipmen t, Equipage; Genera l specification. This

specification esta blishes pa tter ns, met hods, mat erials, and techniques a pplicable

to the pr epara tion of unit loads of nonperisha ble subsistence items by loading th e

shipping containers onto a pallet or within a consolidation container for

shipm ent . The choice of un it load type an d class based upon th e level of

protection provided can be determined from paragraph 6.1 of MIL-L-35078.

Deta iled specificat ion s heet s, MIL-L-35078/1 th rough MIL-L-35078/7, pr ovide th e

requiremen ts for each unit load type and class. The types and classes of un it

loads a re sh own in ta ble 7-1.

Table 7-1. Classification of un it loads of sem iperish able subist ence items (MIL-P-35078)

Types Classes

I - Palletized unit load................................. A - Stra pped or film bonded.

B - Capped and str apped.

C - Sheat hed, capped and stra pped.

D - Shrouded, sheat hed, capped and stra pped.

II - Containerized unit load......................... E - Capped and stra pped fiberboard box.

F - Wood cleated or wirebound, strapped plywood

box.

III - Commercial load base.......................... G - Palletized.

H - Load base.




7-15

Figur e 7-9. Blocking and bra cing top voids.




7-16

Figur e 7-10. Sleeve an d X bra cing.

CARGO CONTAINER S (GENER AL)

DEFINITIONS

The following d efinitions app ly:

T r a n s p o r t e r - A cargo container is a large shipping container in which packed or

un packed mater ial is placed for movement t o a break-bulk point or to an u ltimate

consignee.

MILVAN - The MILVAN is a Government-owned or leased noncollapsible,

reusable cargo container capable of being coupled to another container of like

description. It can be lifted by top or bott om corner fittin gs; can be used eith er

singly or coupled together; an d can be car ried by highway, ra il or wa ter modes of

transportation.

SEAVAN - A SEAVAN is a privately-owned container of various sizes and

configurations which may be leased to the Government for the consolidation

movement of mat erial by highway, rail or wa ter modes of tran sportat ion.

Note - Cargo that is hard to handle in closed vans, such a large, heavy or bulky

items, or m achinery, may be shipped in flat ra cks.

AIR/LAND - The M2 AIR/LAND container is a lightweight intermodal container

that permits land and air freight transportation without rehandling of the

cont ents. The cont ainer is 8 feet in height, 8 feet in width, a nd 20 feet in length.

They have a gross weight capa city of app roximat ely 45,000 pound s. The

container and its contents must not exceed the structural limitations of the

transporting aircraft.




7-17

Figur e 7-11. Blocking and bra cing side voids.

Figur e 7-12. Blocking an d bracing int erior voids




7-18

Stuf f ing - The ter m "stuffing", as r elated to cargo containers, m eans th e placing

of cargo into cargo containers as distinguished from the process of loading

containers on board ship. See MTMC Pam phlet No. 55-2 "Mana gement an d

Stu ffing of Conta iner s".

P URP OSE AND ADVANTAGES OF LARGE C ONTAINERS

P u r p o s e The purpose of cargo containers reduce the number of miscellaneous small

package shipments to unit loads of the best possible size for the direct application

of mechanical han dling equipmen t.

A d v a n t a g e s

The use of mechanical handling procedures increases the speed, security,

accuracy, flexibility, and economy of supply and transportation operations:

• Use of cargo conta iners redu ces the cost of ha ndling an d reh an dling man y

small packages.

• Loss due to damage to containers and supplies during handling and

shipping is redu ced.

• Loss due to pilferaging and misplacement or misrouting of individual

packs is redu ced.

• The consolidation of packs within cargo containers reduces the need for

marking and documentation of individual packs destined for one

consignee.

• Savings are realized through the elimination or reduction of heavy or

expensive sh ipping conta iners.

USE OF MILVANS AND SE AVANS

DE S C R I P T I O N O F MILVAN (MIL-C-52661)

A MILVAN has inside dimensions of 231 inches in length, 92 inches in width, and

87 inches in height . The gross weight ra ting for each 20-foot cont aine r is 44,800pound s. A MILVAN can be coupled to anoth er MILVAN cont ain er to ma ke a

single unit 40 feet in length . A MILVAN ha s th e capa bility of being moved by

semitrailer tractor when used in conjunction with a tandem bogie arrangement

which serves as th e rear wheels. When th e double doors are properly closed, the

MILVAN a ffords wa ter proof pr otection.

DE S C R I P T I O N O F SEAVAN

SEAVANS vary from approximat ely 20 to 40 feet in length. The sta nda rd length

ut ilized by th e military is 40 feet. SEAVANs ar e 8 feet in heigh t an d 8 feet in

width. They have a maximum gross weight capacity of 67,200 poun ds.

SEAVANs are compatible for movement by motor a nd rail an d m ay be st ored for

shipment on specially conta inerized ships. They may be tran sported on a

semitrailer chassis and are lifted easily and loaded, minus the chassis, on board

by modern mater ials-han dling equipment . There are four genera l types an d

th ree sp ecialized types of SEAVANs:

D r y C a r g o C o n t a i n e r

The dr y cargo container is weather proof and is designed to protect th e cargo from

water . It is ideally suited for shipping items packed in domestic packs an d an y

comm odities sus ceptible to wat er dam age. The dry car go cont ain er is complet ely

inclosed an d mu st be loaded and un loaded by ha nd or forklift t ru ck.




7-19

Dr y Ca r go --can vas Top Con t a i ne r

The canvas, or so-called "rag" top container, is similar to the dry cargo container,

but h as a r emovable canva s top. With t he top removed, the cargo can be loaded

and u nloaded by crane as well as forklift. Canvas t op containers a re not 100

percent weatherproof; therefore, all items loaded in such containers must be in

water proof packs or oth erwise be susceptible to water dam age.

F l a t r a c k C o n t a i n e r The flatrack container resembles a flatbed truck with varying styles of side

bracing and corner posts and corner posts and comes in a variety of sizes.

Generally, the flatrack has about two-thirds the cubic capacity of a dry cargo

container, but with t he sam e weight capacity. It is designed to car ry high density

and oddly shaped cargo that require little protection against the elements,

although some ar e equipped with fabric covers. Brackets on th e sides of the bed

facilitate efficient tiedown or banding of heavy items to the bed of the container.

Removable sides facilitate th e loading and un loading by cran e or forklift tru ck.

Reef e r (Re f r i ge r a t o r ) Con t a i ne r

Perishable cargo that must be refrigerated or frozen must be transported in a

refer. Most of the commer cial reefers have stan dar d refrigeration units th at a re

fuel operated for r oad use a nd electrically operated for storage or ocean tra nsit.

The stan dar d container can refrigerate or freeze from ambient t empera tu re to -10

degree Fah renheit .

Figur e 7-13 MILVAN car go cont ain ers coup led for tr an sport




7-20

Figur e 7-14 SE AVAN loaded for highway movement

I n s u l a t e d C o n t a i n e r

This is a specialized container. It is used for cargo tha t sh ould not be subjected to

rap id temper atu re cha nges. It should be used when extreme cha nges in ambient

temperatur es are indicated.

C a r - c a r r i e r

This specialized container is designed to carry two or four privately-ownedvehicles for ocean tr an sport at ion. The cont ain er which car ries four vehicles is 35

feet long and h as double-deck frames. Due to its additional height, the four

vehicle container has one and one-half times the cube capacity of a dry cargo

container.

T a n k C on t a i n e r

This also is a specialized container. It is a sma ll tan k, inclosed in a fram ework,

tha t can be used for small lot sh ipments of bulk liquids.

Wei gh t Di s t r i bu t i on

Distribute the load evenly throughout the container with heavier items on the

bottom.

Car go Mus t be Com p a t i b l e Wi t h t h e S ize o f t he Con t a i n e r

When the density of one commodity is not compatible with the container size,

select a n a dequat e commodity mix tha t will yield th e best cube utilization. At

least 80 percent of the cube sh ould be used.

Wei gh t L i m i t a t i ons

There ar e two overall tran sporter-weight: First, th e rat ed capa city of MILVANs

and SEAVANs; and second, the road-weight limitation imposed by the States

over wh ich t he conta iner m ust tra vel by motor vehicle.




7-21

SHIP MENT OF H AZARDOU S MATER IALSHa zardous mater ials must be compatible with the rem ainder of th e load. Do not

stuff food or medical supplies in the same container as insecticides, chemical

products, radioactive materials, biological materials, poisons, or toxic materials.

Do not ship n oncompatible hazardous ma terials together.

Pack, mark, label, and placard hazardous materials in strict accordance with

Department of Transportation and International Maritime Organization

regulations.

The U. S. Coast Guard regulations prohibit certain explosives and other

ha zardous ma terials from being shipped in cargo containers.

GENERAL R U L E S F O R ST U F F I N G MILVAN S AND SEAVAN S

The general rules discussed below concern the stuffing of general cargo into

MILVANs a nd d ry cargo type SE AVANs.

Place heavy items on t he bottom of the load, ma intaining a n even distribution of

weight t hr oughout t he cargo container .

When stuffing standard 43-inch high modular containers, double-tier them

when ever possible. If double-tiering is not possible, top off the load with "fluff

cargo" of low densit y. "Fluff cargo", which mu st be ma n-ha nd led, should not

exceed 200 pounds per item or pa ck.

Leave several inches of head space between the t op of the load a nd the top of the

car go container so that the load can be r emoved easily with a forklift tru ck.

Pack th e load as t ightly as pra cticable. Do not wedge the load or pack it so

tightly tha t pr oblems will occur dur ing un stuffing operations.

Always position palletized or skidded loads to rest on th eir pallets or skids. Fa cepallet access slots toward the doors to minimize forklift maneuvering during

un stuffing operations.

Never place a heavy crate or box so that it rests on top of, and inside the four

corn ers of th e box benea th it. Place dun na ge over th e lower level of cont ainer s

when den se loads in th e upper t ier may cause dama ge to the cont ainers below.

Place boxes, crates, and cartons, which contain liquids that may leak, on the

bottom of the load whenever practicable.

Keep dru ms tha t contain petroleum products separ ated from general car go. Stow

dru ms with their bungs on top. Pack the dru ms tightly. When possible, pelletize

dru ms. When not palletized, place strips of dun nage between tiers of dru ms. Uselumber, burlap, fiberboard or paper, as applicable, to prevent it from shifting

durin g tran sit. Use dun na ge when it is available for filling spacing between large

boxes or crat es.

A load checker should keep a running account of the weight of individual items

being stu ffed to ensure th e correct total net weight. En ter t he overall load weight

and cube on the loading list or the Transportation Control Movement Document

(TCMD). Bra ce cargo of aver age or high densit y to preven t it from falling out

when t he conta iner doors ar e opened.




7-22

Clos ing an d Sea l ing MILVANs and SEAVANs

Place the shipping document s in th e space provided on th e door. Make sure t hat

both rear doors on MILVANs and SEAVANs are closed by sliding the closure

bolts int o th e holes provided in the body of th e car go cont ain ers. Position the

door handles over the latches in the doors and attach a numbered railway car

seal. MILVANs require that both door latches ar e provided with a seal.

Make sure th at the serial num bers on t he seals correspond with t he nu mbers onthe shipping docum ents. Threa d the seals thr ough the latches on the doors and

sna p th e seals int o th e seal locking devices. Use pa dlocks of app roved design on

car go cont ainer cont aining classified mater ial. Be sure th at k ey control measures

are provided.

Mar kin g of MILVANs an d SE AVANs

Shipment units and shipment units in consolidation will be address marked in

accordance with Military St an dard MIL-STD-129, Stand ard Pra ctice for Military

Marking. The address mar kings for MILVANs an d SEAVANs shall be

accomplished by attaching a waterproofed Military Shipping Label (DD Form

1387) adjacent t o the seal, if required, or a t t he r ear of the van . Data for t he label

will be in conformance with DOD 4500.32R, Military Standard Transportation

and Movement Procedures (MILSTAMP) and MIL-STD-129.



F M 38-701

MCO P 4030.21D

NAVSUP P UB 503

AFP AM(I) 24-209

DLAI 4145.2

1 DECEMBER 1999

B y O r d e r o f t h e S e c r e t a r y o f t h e A r m y :

Official :

ER IC K. SHINSEKI

G e n e r a l , Un i t e d S t a t e s Ar m y

Ch ief of S ta f f

J OEL B. HUDSON

Adm i n i s t r a t i ve As s i s t an t t o t he

S e c r e t a r y o f t h e A r m y

9932206

Active Army, Arm y N ational Guard , and U . S. Arm y Reserve: To be distributed in a ccorda nce

With the initial distribution nu mber 115793, requirement s for F M 38-701.

R. B . FRE DERI CK

Ac t in g , H e a d q u a r t e r s

C om p l e x C om m a n d a n t

M. E. FINLE Y

Cap t a i n , SC, USN

D e p u t y C om m a n d e r

F l ee t Log i st i c s Ope r a t i ons

N a v a l Su p p l y Sy s t e m s C om m a n d

J OHN W HANDY Lt G l USAF

army - fm38 701 - packaging of material - packing

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