FACULTY OF ENGINEERING

(B.Sc. Graduation Project)

ON

"PROCESS ANALYSIS OF CONTAINER

MANUFACTURING"

MECHANICAL ENGINEERING DEPARTMENT

PRODUCTION DIVISION

SUPERVISED BY:-

Dr. Mohammed Moustafa El Zayet

July-2015
 PROCESS ANALYSIS OF CONTAINER
MANUFACTURING

Prepared by:
1.Abd-Allah Mohamed Ali

2.Ali Salah El-den

3.Ammar Hassan kamel

4.Eslam Abdel-aziz Besher

5.Sara Abd EL-maboud

6.Mohamed Sayed Kotb

7.Youssef Ahmed Youssef

SUPERVISED BY:-

Dr. Mohammed Moustafa El Zayet

July-2015
 Acknowledgment
‫ـ‬

All praise be rendered to Allah, peace be upon His Messengers

and their latest Messenger, Muhammad, his family and
Companions and their followed them devotedly till the Day of
Judgment. We thank Allah for helping us finishing this work. In
a sincere try to remember or acknowledge all those who have
dedicated their time and effort to help us to successfully accomplish
this project, we feel indebted to thank those people and
organizations, Dr. Mohammed Moustafa El Zayet, The
supervisor of the project, for his scientific and technical assistance
prof.Dr.Osama mounir dawood, For his assistance in container
project. For their technical support specially for complete the work
in the project Eng. azzam, for provide the container idea for team
members
 Preface
‫ــ‬

The knowledge of cargo containers Fabrication is very useful in

our day-to-day life and one needs to know at least the basics of the
same. The content of this report includes an overview about the
whole manufacturing fundamentals and the processes to be
followed in this category in order to obtain the required final
product.
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
The book contains the description of various processes to be
followed and their analysis for their better understanding. The
various processes included in the report are the Shearing, Bending,
Pressing, Rolling, Welding, Grinding and Powder Coating
Processes, etc. The operation study, machine study, and material
information are clearly mentioned out there.
‫ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
At the end of the book, there is also a portion of future
scope, in which some drawbacks and improvements needed, can be
acknowledged. In last words, this report is all about the industrial
aspect related to container fabrication.
 ‫‪INDEX‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪Contents‬‬

‫‪Contents‬‬
‫‪CONTENTS‬‬ ‫‪i‬‬

‫‪FIGURE LIST‬‬ ‫‪iii‬‬

‫‪TABLE LIST‬‬ ‫‪v‬‬

‫‪NOMENCLATURE‬‬ ‫‪vi‬‬

‫‪Chapter1‬‬ ‫‪INTRODUCTION‬‬
‫‪INTRODUCTION....................................................................................................................... 1‬‬

‫‪OBJECTIVES............................................................................................................................. 2‬‬

‫‪1.1 TYPICAL DIMENSIONS OF STANDARD SHIPPING CONTAINERS....................... 3‬‬

‫‪1.2 TYPES OF CONTAINERS.................................................................................................. 5‬‬

‫‪Chapter 2‬‬ ‫‪COMPONENTS OF CONTAINER‬‬

‫‪2.1 TABLE OF COMPONENTS................................................................................................ 7‬‬

‫‪2.2 CHEMICAL COMPOSITION OF MATERIAL............................................................... 14‬‬

‫‪CHAPTER 3‬‬ ‫‪CONSTRUCTION OF CONTAINER‬‬

‫‪3.1 GENERAL............................................................................................................................. 15‬‬

‫‪3.2 PROTRUSION...................................................................................................................... 17‬‬

‫‪3.3 CORNER FITTINGS............................................................................................................ 18‬‬

‫‪3.4 BASE FRAME STRUCTURE.............................................................................................. 19‬‬

‫‪3.5 FLOORING............................................................................................................................ 21‬‬

‫‪3.6 REAR FRAME STRUCTURE............................................................................................. 22‬‬

‫‪3.7 DOOR...................................................................................................................................... 27‬‬

‫‪3.8 ROOF STRUCTURE............................................................................................................ 30‬‬

 ‫‪INDEX‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪Contents‬‬
‫‪3.9 TOP SIDE RAIL......................................................................................................................32‬‬

‫‪3.10 SIDE WALL...........................................................................................................................33‬‬

‫‪3.11 FRONT STRUCTURE......................................................................................................... 35‬‬

‫‪CHAPTER 4‬‬ ‫‪PROCESS SEQUENCE‬‬

‫‪4.1 SHEARING PROCESS.......................................................................................................... 39‬‬

‫‪4.2 PLASTING AND PRIMING PROCESS............................................................................. 42‬‬

‫‪4.3 CORRUGATION (ROLL BENDING) PROCESS.............................................................. 44‬‬

‫‪4.4 BENDING PROCESS.................................................................................................................................46‬‬

‫‪4.5 STAMPING PROCSS............................................................................................................. 51‬‬

‫‪4.6 WELDING PROCESS.............................................................................................................52‬‬

‫‪4.7 FINISHING AND PAINTING PROCESS............................................................................55‬‬

‫‪CHAPTER 5‬‬ ‫‪MANUFACTURING PROCESS‬‬

‫‪5.1 PHASE (1) SUB ASSEMBLY………………….……………………………………………56‬‬

‫‪5.2 PHASE (2) MAIN ASSEMBLY……………….….…………………………………………62‬‬

‫‪5.3 PHASE (3) FINISHING……….………………….…………………………………………64‬‬

 ‫‪LIST OF FIGURES‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪Figure‬‬ ‫‪Page‬‬
‫)‪Fig. (1-1) Types of container ….……………………………………………………….…… (5, 6‬‬

‫)‪Fig. (4-1) Hydraulic shearing machine………..…………………………………………… (39‬‬

‫)‪Fig. (4-2) Cutting of steel sheets…………………………………………………………….. (40‬‬

‫)‪Fig. (4-3) Stages of shearing operation………………………………………………..……. (42‬‬

‫)‪Fig. (4-4) Roll conveyor sand blasting machine……………….…………………….…….. (43‬‬

‫)‪Fig. (4-5) Portable blasting machine with a gun ……..…………………………………….. (43‬‬

‫)‪Fig. (4-6) Sheet metal ……….…………………………………….…………………..……… (44‬‬

‫)‪Fig. (4-7) Corrugated sheet metal ……………………….…………………………..……….(44‬‬

‫)‪Fig. (4-8) Corrugated parts of container ……………………………………………………. (45‬‬

‫)‪Fig. (4-9) Corrugation machine……........……….………………….. ……………………… (45‬‬

‫)‪Fig. (4-10) Bending machine………………………………………………………….…...…. (47‬‬

‫)‪Fig. (4-11) Press brakes main parts movements …………………………….………………(48‬‬

‫)‪Fig. (4-12) U- bending with 90 degrees ……………….…………………………………..… (49‬‬

‫)‪Fig. (4-13) Offset bending ……..……………………………..........…………………..…….. (49‬‬

‫)‪Fig. (4-14) Square tube bending……….………………………………...…..………………..(50‬‬

‫)‪Fig. (4-15) Bending with a flange ……………………….……………………………………(50‬‬

‫)‪Fig. (4-16) Stamping process……........…………………..…………………..……………… (51‬‬

‫)‪Fig. (4-17) Welding wall panels (tack welding)………………………………………………(52‬‬

‫)‪Fig. (4-18) Seam welding process ….…………………………………………………………(53‬‬

‫)‪Fig. (4-19) Seam welding machine ………..………………………………………………… (53‬‬

‫)‪Fig. (4-20) MIG welding machine…………………………………………………………… (53‬‬

‫……………………………………………………………………‪Fig. (4-21) Roof welding‬‬ ‫)‪(54‬‬

‫)‪Fig. (4-22) Finishing and painting process……………….………………………………… (55‬‬

 ‫‪LIST OF FIGURES‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪Page‬‬
‫)‪Fig. (4-23) painting inside and outside of the container.… ……………………..…………….. (55‬‬

‫)‪Fig. (5-1) Unrolling and cutting of steel sheets ……………………….……………………….. (56‬‬

‫)‪Fig. (5-2) Shot blasting and priming of sheets ………………………………………………… (57‬‬

‫)‪Fig. (5-3) Roller pressing corrugated side panels……..……………………………………….. (57‬‬

‫)‪Fig. (5-4) Assembling side panel to tope side real ……………………………………………... (58‬‬

‫)‪Fig. (5-5) Corrugated front panels ….………………………………………………………….. (59‬‬

‫)‪Fig. (5-6) Rear end frame assembly………..…………………………………………………….(60‬‬

‫)‪Fig. (5-7) Base frame assembly…………………………………………………………………...(60‬‬

‫)‪Fig. (5-8) Roof sheet die stamping and welding…………………………………………… … (61‬‬

‫)‪Fig. (5-9) Main assembly of the side panels……………….…………………………………… (62‬‬

‫)‪Fig. (5-10) Tack welding roof sheets in place ……..…………………………………………… (62‬‬

‫)‪Fig. (5-11) Secondary shot blasting……….……………………………………………………...(63‬‬

‫)‪Fig. (5-12) Primer painting ……………………….……………………………………………...(63‬‬

‫)‪Fig. (5-13) Painted units exit drying oven ………………………………………………………(64‬‬

‫)‪Fig. (5-14) Applying floor sealant……..………………………………………………………….(64‬‬

‫)‪Fig. (5-15) Securing floor sheets………………………………………………………………….(65‬‬

‫)‪Fig. (5-16) Applying door vents for air flow ….…………………………………………… …..(65‬‬

‫)‪Fig. (5-17) Markings applied………..……………………… ………………………………….. (66‬‬

‫)‪Fig. (5-18) Water testing chamber……………………………………………………………… (66‬‬

‫)‪Fig. (5-19) Floor strength testing……………………………………………………………….. (67‬‬

 ‫‪LIST OF TABLES‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪TABLE‬‬ ‫‪Page‬‬

‫)‪Table (1-1) Typical weights of standard shipping containers……………...…….. (3‬‬

‫)‪Table (2-1) components of container………………………..……………….…….. (7‬‬

‫)‪Table (4-1) portable blasting machine specifications……….……………...……. (44‬‬

‫)‪Table (4-2) corrugation machine specifications...…….………….………………. (46‬‬

 ‫‪NOMENCLATURE‬‬
‫ـــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪Symbols‬‬
‫‪Yield point =Y.P‬‬

‫‪Tensile stress= T.S‬‬

‫‪Thickness = t‬‬

‫‪Steel casted weldable= SCW‬‬

‫‪Structural steel = SS‬‬

‫‪Acrylonitrile Butadiene Styrene = ABS‬‬

‫‪Ethylene propylene diene monomer = EPDM‬‬

‫‪Steel grades = SC‬‬

 CHAPTER (1)
Introduction
 CHAPTER (1) INTRODUCTION

Many nations in the World have more than enough of specific resource or product
corgeography to produce all the goods and food required by their population. Hence, the
international movement of goods has become inevitable. The movement of such goods
needs to be carried out either through land or water or air. Movement of goods through
Sea become more popular because of its convenience and cost effectiveness as compared
to other modes of transportation.
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
Containerization is the system of transportation of cargo in large units in intermodal
containers for minimizing the handling effort at various transfer points from one mode to
the other. The unitized transport system known as the containerization system has the
following advantages:

− Handling in large units and time saving

− Security against theft, pilferage of goods
− Containers available for carrying specific type of products like liquids, gas, refrigerated
products, etc
− Flexibility between different types of transport
− Multiple handling of the content in the container is eliminated
− Labor saving
− Little cargo damage.
 INTRODUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
Objectives
1. To study the production and situation of container industry in EGYPT mainly in
Eastern region
2. To study the feasibility of investment in production capacity expansion of
container plant Industrial group
3. To study the sensitivity of Manufacturing process for container
4. To study the Sequence of the production operation
5. To make model for each part Using CAD pro. as solid work
6. To learn how to make assembly for container parts
 ‫‪INTRODUCTION‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
‫‪1.1‬‬ ‫‪Typical Dimensions & weights of Standard Shipping Containers‬‬
 ‫‪INTRODUCTION‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫)‪Typical Dimensions & weights of Standard Shipping Containers Table (1-1‬‬

 ‫‪INTRODUCTION‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
‫‪1.2‬‬ ‫‪Types of containers‬‬
 ‫‪INTRODUCTION‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪Fig (1-1) Types of containers‬‬

 CHAPTER (2)
Components of
container
 CHAPTER (2) COMPONENTS OF CONTAINER

2.1 Table Of Components

NO NAME OF PART MODELING SKETCH MATERIAL No.OFF

Anti-Corrosive
1 Steel: CORTEN A
Roof panel
Y.P. : 35 kg/sq. mm
5
T.S. : 49 kg/sq. mm

Anti-Corrosive
2 Steel: CORTEN A
Side panel
Y.P. : 35 kg/sq. mm
5
T.S. : 49 kg/sq. mm

Anti-Corrosive
3 Steel: CORTEN A
Front end panel
Y.P. : 35 kg/sq. mm
2
T.S. : 49 kg/sq. mm

Anti-Corrosive
Steel: CORTEN A
4 Door panel Y.P. : 35 kg/sq. mm
2
T.S. : 49 kg/sq. mm

Anti-Corrosive
5 Steel: CORTEN A
Front corner post
Y.P. : 35 kg/sq. mm
2
T.S. : 49 kg/sq. mm

Anti-Corrosive
Steel: CORTEN A
Outer
Y.P. : 35 kg/sq. mm
T.S. : 49 kg/sq. mm
2
6 Rear corner
 post Rolled high tensile
steel: SM490A
or equivalent
Inner Y.P. : 33 kg/sq. mm
T.S. : 50 kg/sq. mm
2

Anti-Corrosive
Steel: CORTEN A
7 Cross member Y.P. : 35 kg/sq. mm
18
T.S. : 49 kg/sq. mm

Anti-Corrosive
Steel: CORTEN A
8 Bottom side rail Y.P. : 35 kg/sq. mm
2
T.S. : 49 kg/sq. mm

Anti-Corrosive
Steel: CORTEN A
Top side Square
9 rail tube Y.P. : 35 kg/sq. mm
T.S. : 49 kg/sq. mm
2

Anti-Corrosive
Steel: CORTEN A

Y.P. : 35 kg/sq. mm
1
11 Door sill T.S. : 49 kg/sq. mm

Anti-Corrosive
Steel: CORTEN A
11 Front bottom rail
Y.P. : 35 kg/sq. mm
T.S. : 49 kg/sq. mm
1
 Anti-Corrosive
Steel: CORTEN A
.
12
Top end rail
Y.P. : 35 kg/sq. mm
T.S. : 49 kg/sq. mm
1

Anti-Corrosive
Steel: CORTEN A
Upper
Y.P. : 35 kg/sq. mm
1
T.S. : 49 kg/sq. mm

13 Door header

Anti-Corrosive
Steel: CORTEN A
1
Lower Y.P. : 35 kg/sq. mm
T.S. : 49 kg/sq. mm

Anti-Corrosive
2
14 Floor space Steel: CORTEN A

Anti-Corrosive
15 Top bottom end rail Steel: CORTEN A
(Square tube )
Y.P. : 35 kg/sq. mm
1
T.S. : 49 kg/sq. mm
 Anti-Corrosive
Steel: CORTEN A
16 Door edge member
Y.P. : 35 kg/sq. mm
1
T.S. : 49 kg/sq. mm

Casted weld able

steel: SCW480
17 Corner fitting 8
T.S. : 49 kg/sq. mm
Y.P. : 28 kg/sq. mm

Stainless; 4
18 Stainless door seal SUS304
retainer trip

Forged weld able

steel: 20Mn

19 Cam ( LH / RH ) T.S. : 44 kg/sq. mm

8
Y.P. : 23 kg/sq. mm

Forged weld able

steel: 20Mn

20 Keeper ( LH / RH ) T.S. : 44 kg/sq. mm

8
Y.P. : 23 kg/sq. mm

21 8
Bearing bracket L SS400
22 Bearing bracket S
SS400 4

Forging 20Mn
4
23 Handel

20Mn
Press 4

forging
SS400 4
24 Retainer
catch

Retainer forging SS400

25 plate 4

SS400 8
26 Bush

27 Handel hub
SS400
4
28 Anti-rack ring
SS400 8

8
29 Hinge blade
SC25

Hinge Stainless steel:

SUS304
8
accessor
y

Hinge
30 accessory

Hinge SS400 16
lug

4
31 Ventilator ABS resin
labyrinth type

32 Door seal EPDM 2

rubber
33 Door screw SS41 N
M10×25

34 Tapping screw Stainless steel: N

M9×45

Stainless steel:
35 Stainless blind rivet M4×8
N

36 Lashing ring 20
S25C

37 CSC plate Stainless steel:

250×200×0.8 1

Hardwood
plywood,
38 Wooden floor 19-ply 6

Table Of Components (2-1)

 COMPONENTS OF CONTAINER
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
2.2 Chemical composition of Material
2.2.1 corten steel (Weathering steel)
"Corten steel", is a group of steel alloys which were developed to eliminate the need for
painting, and form a stable rust-like appearance if exposed to the weather for several
years . The original COR-TEN received the standard designation A 242 ("COR-TEN A") from
the ASTM International standards group. Newer ASTM grades are A 588 ("COR-TEN B")
and A 606 for thin sheet. All alloys are in common production and use.

Corten A – weather resistant steel created by alloying copper, chromium and nickel.
WELDING - COR-TEN A plates can be easily welded using all common procedures used for
mild steel plates (spot, TIG, MIG, MAG, electrode etc.)

Chemical composition of Cor-ten grades

Element C Si Mn P S Cr Cu Ni

Cor-ten A 0.12 0.25-0.75 0.20-0.50 0.01-0.20 0.030 0.50-1.25 0.25-0.55 0.65

2.2.2 SS400 ( Structural Steel)

Alloy Composition Iron
Iron (Fe)99.3 to 100 % Silicon (Si)0 to 0.4 % Carbon (C)0 to 0.26 % Sulfur (S)0 to 0.05 %
Phosphorus (P)1 to 1.14 % SS411 Mechanical Properties Density (kg/m3) 7861 Young’s
Modulus (GPa) 190-210 Tensile Strength (MPa) 400 – 510 MPa Yield Strength (MPa)
205-245 MPa Poisson's ratio 0.26 SS400 Hardness Brinell Hardness (HB) 160
 CHAPTER (3)
Constructions of
container
CHAPTER (3) CONSTRUCTION

3.1 General
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.1.1 The container will be constructed with steel frames, fully vertical-corrugated
Steel sides and front wall, horizontal-corrugated steel double doors at rear end,
Die-stamped steel roof and corner fittings.

3.1.2 All welds of exterior including the base frames will be continuous welding
Using CO2 gas, but inner part of each bottom side rail will be fastened by staggered
Stitch welding.

3.1.3 Interior welds - when needed - will be stitched with a minimum bead length of
15mm.

3.1.4 Gaps between adjacent components to be welded will not exceed 3mm or the
Half thickness of the parts being welded.

3.1.5 Chloroprene sealant is to be applied at periphery of floor surface and inside

unwelded seams, butyl sealant is used to caulk at invisible seam of floor joint area
And between door gasket and frame.

3.1.6 The wooden floor will be fixed to the base frames by zinc plated self-tapping
Screws.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.2 Protrusion

3.2.1 The plane formed by the lower faces of the bottom side rails and all transverse
Members shall be positioned by 12.5mm +5/-1.5mm above the plane formed by
The lower faces of the bottom corner fittings
.
3.2.2 The top corner fittings are to protrude a minimum of 6mm above the highest
Point of the roof.

3.2.3 The outside faces of the corner fittings will protrude from the outside faces of
The corner posts by minimum 4mm for side structure and 4mm for front end
Structure.

3.2.4 The outside faces of the corner fittings will protrude from side wall by nominal
8mm and from the outside face of the end wall by 8mm.

3.2.5 Under maximum payload, no part of the container will protrude below the
Plane formed by the lower faces of the bottom corner fittings at the time of
Maximum deflection.

3.2.6 Under 1.8 x maximum gross weight, no part of the container will protrude more
Than 6.0mm below the plane formed by the lower faces of the bottom corner
Fittings at the time of maximum deflection
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.3 Corner fittings

The corner fittings will be designed in accordance with ISO 1161 (Amd.1990) and
manufactured at the works approved by classification society.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.4 Base frame structure

Base frame will be composed of two (2) bottom side rails, a set of forklift pockets and
Totally eighteen (18) cross members.

3.4.1 Bottom side rail

Each bottom side rail is built of 48x158x30x4.5mm thick cold-formed channel section
Steel made in one piece. The floor guide rails of 3.0mm thick pressed angle section
Steel are provided to the bottom side rails by staggered stitch welding.

The lower flange of the bottom side rail is outward so as to facilitate easy removal of
The cross members during repair and of less susceptible corrosion.

Reinforcement plates are to be made of 4.0mm thick, flat steel plates. The plates are
Welded to bottom corner fitting.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.4.2Forklift pockets

Each forklift pocket is built of 3.0mm thick full depth flat steel top plate and two 200
mm deep x 6.0 mm thick flat lower end plates between two channel section cross
members. The one set of forklift pockets is designed in accordance with ISO
requirements

3.4.3 Cross member

The cross members are made of pressed channel section steel with a dimension of
45x122x45x4.5mm for the normal areas and 75x122x45x4.5mm for the floor butt
Joints. The cross members are placed fully to withstand floor strength and welded to
each bottom side rail.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.5 Flooring

The floor will consist of six pieces plywood boards, floor centre rail, and self-tapping
Screws.

3.5.1Floor

The wooden floor to be constructed with 28mm thick 19-ply hardwood plywood
Boards are laid longitudinally on the transverse members between the steel floor
Centre rail of 4.0mm thick flat bar and the 3.0mm thick pressed angle section steel
Floor guide rails stitched welded to the bottom side rails.
The floorboards are tightly secured to each transverse member by self-tapping
Screws, and all butt joint areas and peripheries of the floorboards are caulked with
Sealant.
1) Wood species :Apitong or Keruing
2) Glue : Phenol-formaldehyde resin.
3) Treatment :

a) Preservative: BASILEUM SI-84 or others.

b) In accordance with Australian Health Department Regulations. Average

Moisture content will be 12% before installation

 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
3.5.2Self-tapping screw

Each floor board is fixed to the transverse members by zinc plated self-tapping
Screws that are 8.0mm dia. shank x 16mm dia. head x 45mm length, and fastened by
Four screws per cross member but five screws at joint areas. Screw heads are to be
Countersunk through about 2mm below the floor top surface.

3.6 Rear frame structure

The rear frame will be composed of one door sill, two corner posts, one door header
and four corner fittings, which will be welded together to make the door-way.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.6.1 Door sill

The door sill to be made of a 4.5mm thick pressed open section steel is reinforced by
four internal gussets of a 4.0mm thick at the back of each locking cam keeper location.
The upper face of the door sill has a 10mm slope for better drainage.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.6.2 Rear corner post

Each rear corner post of hollow section is fabricated with pressed, 6.0mm thick, steel
outer part and 40x113x12mm hot-rolled channel section steel inner part, which are
welded continuously together to ensure a maximum width of the door opening and to
give a sufficient strength against stacking and racking forces.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.6.3 Door header

The door header is constructed with a 4.0mm thick pressed “U” section steel
lower part having four internal gussets at the back of each locking cam keeper location
and a 3.0mm thick pressed steel upper part, which are formed into box section by
continuous welding.
 ‫‪CONSTRUCTION‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.7 Door

3.7.1 Each container will have double wing doors at rear end frame, and each door
will be capable of swinging approximately 270 degrees.

3.7.2 Each door is constructed with pressed, 3.0mm thick, channel section steel
Horizontal frames for the top and bottom, 100x50x2.3mm and 100x50x3.2mm
Rectangular hollow section vertical frames for the post side and centre side of door
Respectively, 2.0mm thick horizontally corrugated steel door panel, which are
continuously welded within frames.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
3.7.3 Door panel

3.7.4 The left-hand door can not be opened without opening the right-hand door
When the container is sealed in accordance with TIR requirements
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.7.5 Each door is suspended by four hinges being provided with stainless steel
pins

3.7.6The door gasket made of an extruded triple lip type (J-type) EPDM rubber is
Installed to the door peripheral frames with stainless steel gasket retainers and
fastened by stainless steel blind rivets at a pitch of 150mm.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.8 Roof structure

The roof will be constructed with five five-corrugated (die-stamped) steel panels and
Four corner protection plates.

3.8.1 Roof panel

The roof panel is constructed with 2.0mm thick die-stamped steel sheets having
About 6.0mm upward smooth camber, which are welded together to form one panel
And continuously welded to the top side rails and top end rails
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.8.2 Protection plate

Each corner of the roof in the vicinity of top corner fitting is reinforced by 3.0mm thick
Rectangular steel plate to prevent the damage caused by mishandling of lifting
Equipment.
 ‫‪CONSTRUCTION‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪3.9 Top side rail‬‬

‫‪Each top side rail is made of 60x60x3.0mm thick square hollow section steel.‬‬
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.10 Side wall

The trapezium section side wall is constructed with 1.6mm thick fully vertically
Continuous corrugated steel panels at the intermediate area and 2.0mm thick fully
vertically continuous corrugated steel panels at both ends which are butt welded
together to form one panel and continuously welded to the side rails and corner posts.
 ‫‪CONSTRUCTION‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪.‬‬
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.11 Front structure

Front end structure will be composed of one bottom end rail, two corner posts, one
top end rail, four corner fittings and an end wall, which are welded together.

3.11.1 Bottom end rail

The bottom end rail to be made of a 4.0mm thick pressed open section steel is
reinforced by three internal gussets.
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.11.2 Front corner post

Each corner post is made of 6.0mm thick pressed open section steel in a single piece,
and designed to give a sufficient strength against stacking and racking forces.

unfold
 CONSTRUCTION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

3.11.3 Top end rail

The top end rail is constructed with 60x60x3.0mm thick square hollow section steel at
Lower part and 3.0mm thick pressed steel at upper part.

3.11.4 Front wall

The trapezium section front wall is constructed with 2.0mm thick vertically corrugated
steel panels, butt welded together to form one panel, and continuously welded to
front end rails and corner posts.
 CHAPTER (4)
Processes sequence
 CHAPTER (4) process sequence

• It all starts with sheet steel that

Shearing arrives normally in coil form at a
process local steel service centre where
it’s de-coiled into flat sheet, burr
edge is slit away and the sheet is
cut to size

• Shot blasting and priming blasting &

of sheets. priming
process

corrugation • corrugation(roll bending) includes

process creating corrugation on side panel
sheets which helps increase the
strength of the side wall
• set camber to facilitate drainage
when containers are in use, it’s
important to avoid water pooling die
on the roof stamping
process
• The base frame slides in first, next
the front and rear end frames
welding followed by side walls and the entire
process structure is tack welded together.

• coating and the container Painting

is then baked in an oven. &drying
process • sealant is applied to the floor
• plastic ventilators are riveted into
position over the ventilation holes.
other • galvanized lock rods with bushes and
retainers, swivel customs catches and
processes door handles are bolted on in
• Testing entails stacking test, racking
compliance with procedures required
tests, wall strength test inspection for approval of transportation under
checks repair and touch up then customs seal.
takes place in the outside container
yard before delivery for shipment.
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

4.1 Shearing Process:

It all starts with sheet steel that arrives normally in coil form at a local steel service
center where it’s de-coiled into flat sheet, burr edge is slit away and the sheet is cut to
size

4.1.1 Difference between Shear and mechanical press:

Shearing machine usually comes in two types: mechanical and hydraulic
The work principle of mechanical shear is nearly the same as that of mechanical press
.However , the mechanical shear produces excessive noise , has no overload capacity ,
and is very difficult to adjust the blade gap.

4.1.2 Hydraulic Shears

Hydraulic shears are used in high volume metal fabricating operations that require the
ability to accurately and quickly cut and score sheets of metal. Hydraulic shears,
contrary to their name, look nothing at all likes shears. Instead, the cutting mechanism
is enclosed inside a large stand-alone unit that can be as much as 10 feet tall and 16 feet
long.
Multiple sets of sharp blades inside the hydraulic shears cut to the metal to the
specification of the operator, while support arms stabilize the metal as it is being cut.

Hydraulic shears are favored for high intensity metal manufacture because they are
quick, quiet, and capable of operating continuously. Hydraulic shears can
accommodate a range of sizes of metal plate, depending upon the manufacturer and
model. Many can cut through up to an inch of metal and are also used in demolition to
sheared metal into more manageable
parts for recycling. Figure (4-1) most
hydraulic shears are designed for over-
floor installation and do not need to build
into the factory, which means that they
can also be moved around as production
lines need change.

The metal to be cut is inserted into the

hydraulic shears and held in place with
clamps so that it does not shift position
during the cutting process.
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

If a 90° cut is required, a squaring arm or back gauge will be employed to ensure an
even, smooth cut. A small burr may be formed by the edge of the blade, which can be
ground off.

Users of hydraulic shears should be aware, however, that small marks may be left by
the blades and holding clamps, and that they should compensate accordingly

4.1.3 Cut to length:

It’s very feasible to mention cut to length lines while explaining container
manufacturing, the cut to length lines cut an entry mother strip in cross section,
forming sheets that are suitably stacked in compact and square packages
The main benefit of cut to length lines is High productivity by minimizing down times by
means of automatic changes of leveler rolls, shear knives and non-stop alternative
stacking in up to four different stacking stations.

Figure (4-2)
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
4.1.4 What happens during Shearing Process?

Shearing is the process of cutting off of sheets using a die and punch, applying shear
stress along the thickness of the sheet.
A die and punch or pair of blades are used in shearing. Shearing happens by severe
plastic deformation locally followed by fracture which propagates deeper into the
thickness of the blank.

The clearance between the die and punch is an important parameter which decides the
shape of the sheared edge. Large clearance leads to rounded edge. The edge has
distortion and has burr.
The shearing load is also higher for larger clearance. For harder materials and larger
sheet thickness, larger clearances are required. Generally, clearance can vary between
2% and 8% of the sheet thickness. Usually shearing begins with formation of cracks on
both sides of the blank, which propagates with application of shear force.

A shiny, burnished surface forms at the sheared edge due to rubbing of the blank
along the shear edge with the punch or the die wall.
Shear zone width depends on the speed of punch motion. Larger speed leads to narrow
shear zone, with smooth shear surface and vice-versa. A rough burr surface forms if
clearance is larger. Similarly, a ductile material will have burr of larger height.

Shearing a blank involves plastic deformation due to shear stress. Therefore, the force
required for shearing is theoretically equal to the shear strength of blank material. Due
to friction between blank and tool, the actual force required is always greater than the
shear strength. Variation of punch force during shearing process is shown below in
figure (4-3)
For reducing the shearing force, the cutting edges of the punch are made at an angle.
This ensures cutting of a small portion of the total length of cutting.
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
4.1.5 Stages of shearing operation

Figure (4-3)

(1) Just before punch; (2) punch pushes into work, causing plastic
Deformation; (3) punch penetrates into work; and (4) fracture is initiated

4.2 Blasting and priming process

4.2.1 What is blasting process?

Blasting is a process used to clean, strengthen and polish metal

It is used in almost industries that use metal as aerospace, automotive construction and
shipping containers

4.2.2 Types of blasting

1-Sand blasting

2-Shot blasting

3-Wheel blasting

4-Air blasting

5-Abrasive blasting
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

4.2.3 Blasting machines

Blasting may be carried out on machine as in Figure (4-4) which is called roll conveyor
blasting machine

Figure (4-4) roll conveyor sand blasting machine

But the most commonly used is the portable blasting machine with a gun; see

Figure (4-5)

Figure (4-5) portable blasting machine with a gun

 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

4.2.4 Portable sand blaster specifications

Q2610 portable sandblaster
Item Description
Machine Type Sandblaster
Brand Name HACHIEVE
Fuel Electric
Material Metal / Coil
Model Number Q2610
Power(KW) 50-200KW
Place of Origin Shandong, China (Mainland)
Power supply AC380V/3p 50HZ
Compressed air consumption 6.3m3/min; 0.5-0.7MPa
Price US $40,000-400,000 per set
Table (4-1) Q2610 portable sandblaster

4.3 Corrugation (Roll Bending) process

4.3.1 What is corrugation process?
Corrugation process is to press the steel sheet, figure (4-6) through rolling into all kinds
of trapezoidal pattern sheet as in figure (4-7). Corrugation process is carried out using
the process of roll forming. This modern process is highly automated to achieve high
productivity and low costs associated with lab our. In the corrugation process sheet
metal is pulled off huge rolls and through rolling dies that form the corrugation.

Figure (4-7) corrugated sheet metal Figure (4-6) sheet metal

 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

4.3.2 Advantages of corrugation

Because of high length, sheets become weak and easy to bend so we use corrugation
process to increase stiffness and shear buckling strength and make sheets light weight
and high strength.

4.3.3 Parts to be corrugated

In figure (4-8), main parts of container to be corrugated
a-Both of side walls

b-Front panel or (back wall panel)

Figure (4-8) corrugated parts

4.3.4 Corrugation machine

It is a machine used to corrugate sheet metal. See figure (4-9)

Figure (4-9) Corrugation machine

 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
4.3.4 Corrugation machine specifications

Product Name Item Description

Coil width Depend on your profiles
Working speed 12-15 m/min
Roll station about 16 - 24 stations
Grade 45 steel, polished and coated with chro
Material of roller
me
Material of main sha
45﹟ steel
ft
Corrugated
Sheet / Diameter roller 70mm
Trapezoidal Main power 7.5KW
Roof Panel Roll Transmission by single Chains 1.5 inch
Forming Machine drive parts Adopt protect cover
Machine
Machine station Adopt new station with chrome
7500x1500x1300(mm) L x W x H need 1x40G
Size of main machin
P
e
container
Weight about 8000Kgs
Color of machine Blue ( or depend on customer’s request)
Machine legs Four legs (made from metal) in 350mm
Price US $18000-125000 per set
Table (4-2) corrugation machine specifications

4.4 BENDING PROCESS:

Bending is a process by which metal can be deformed by plastically deforming the

material and changing its shape. The material is stressed beyond the yield strength but
below the ultimate tensile strength.

The surface area of the material does not change much. Bending usually refers to
deformation about one axis.

Bending is a flexible process by which many different shapes can be produced.

Standard die sets are used to produce a wide variety of shapes.
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

The material is placed on the die, and positioned in place with stops and/or gauges. It is
held in place with hold-downs. The upper part of the press, the ram with the
appropriately shaped punch descends and forms the V-shaped bend
Bending is done using Press Brakes. Press Brakes normally have a capacity of 20 to 200
tons to accommodate stock from 1m to 4.5m (3feet to 15 feet).
Larger and smaller presses are used for specialized applications. Programmable back
gauges, and multiple die sets available currently can make for a very economical
process

4.4.1 Machine parts:

The machine has a stationary bed or anvil

and a slide (ram or hammer)
which has a controlled reciprocating motion
toward and away from the bed surface and
at right angle to it. The slide is guided in the
frame of the machine to give a definite path
of motion
Figure (4-10)

A form of open-frame single-action press that is comparatively wide

Between the housings, with a bed designed for holding long, narrow forming edges or
dies. Used for bending and forming strip, plate, and sheet (into boxes, panels, roof
decks, and so on) Dies used in presses for bending sheet metal or wire parts into various
shapes. The work is done by the punch pushing the stock into cavities or depressions of
similar shape in the die or by auxiliary attachments operated by the descending punch.
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

4.4.2 Press braks main parts movements (How the machine works)

The blank (1) is moved on a horizontal plane by a manipulator (2) that moves across
the plane quickly and accurately. A sheet rotator (3) fitted on the manipulator places
the side to be bent in front of the press equally quickly and accurately.
The blank holder (4) holds the blank firmly, or releases it as quickly as possible. The
bending unit (5), featuring interpolated movement and appropriate blades (6), can
thus make any number of bends, up or down, in rapid succession This bending method
has the enormous advantage that part of the blank does not move during bending,
which makes automating movements of the work piece that much easier.

Figure (4-11)

4.4.3 Bending techniques:

In containers there are many bending techniques used such as:

1- U bending with 90 degrees

U shaped rail can be produced by many ways, such as wiping die or by standard punch
it just as simple as 90 degrees V bending , we just rotate the work piece and apply
another 90 degrees V at the other end
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

Figure (4-12)
2- Offset bending
This bending is made by a punch and dies which have the same dimensions of the work
piece

Figure (4-13)

3- Square tube bending

Square tube is a little more complicated than previous processes,
1- We design the folds positions as following
2- Applying bending at corner 2, then 3 with respect to the clearance for the punch to
log out from the work piece
3- Appling the welding across line 4 to get finished square tube
 ‫‪PROCESS SEQUANCE‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫)‪Figure (4-14‬‬

‫‪5- Bending with a flange‬‬

‫)‪Figure (4-15‬‬
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
4.5 Stamping process
Roof panels and door Panels
These panels are a little different, they are made using another types of punches, which
have the same shape of the stamped pattern Metal stamping dies are the devices used in
metal stamping machines. Each metal stamping machine can have one or more than
one dies depending on the kind of machine. Dies are the main components in metal
stamping machines that do the actual
casting, punching; Figure (4-16)
Cutting and shaping of the metal
sheet. The basic die operations are
drawing, shearing and bending. In
metal stamping, the metal sheets are
placed in a die or a press tool which
has a specially designed cavity that
gives the preferred shape to the metal
sheet. The upper part of the die
connects to the press slide while the
lower component connects to the press
bed. A specific component known as
the punch pushes the metal sheet through the die, thus performing the actual
shaping operation. The patterns on the dies can be used to emboss or give three-
dimensional lettering on the final product.
Dies are placed in sheet metal panels either alone or as a series of presses in a press line.
Metal stamping dies and presses can have different input variables on the bases of
tonnage, press parallelism, shut height, nitrogen pressure in dies, counterbalance
pressure and press speed.
These variables can influence the
quality of the stamping panel, particularly during die setup. The same stamping press
can be reused by replacing one set of dies with another. The placement of dies in a
press is known as die setup. Die setup decides the shut height and binder force. The
number of components produced in a die setup is known as a batch. There are many
different kinds of dies such as single station dies, multiple station dies, compound dies,
progressive dies and tandem press lines. Most dies are designed by the metal stamping
companies who use advanced technologies like CAD to design them according to
customer specifications.
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
4.6 WELDING PROCESS
What is welding?

Welding is the process of permanently joining two or more metal parts, by melting
both materials. The molten materials quickly cool, and the two metals are permanently
bonded. It is used for assembly the container parts

4.6.1 Parts to be welded

4.6.1.1 Side wall assembly
A-welding side wall panels

Steel panels are welded to form a complete side wall using tack welding as initial
welding, see Figure (4-17) .The expression “Tack Welding” refers to a temporary weld
used to create the initial joint between two pieces of metal being welded together. That
means tack welding is not the main welding but the initial

Figure (4-17) tack welding the side wall panel

Then use the main welding (seam welding) See Figure (4-18, 4-19)

Seam welding is a process that produces a weld at the faying surfaces of two similar
metals. The seam may be a butt joint or an overlap joint and is usually an automated
process.
 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

Figure (4-18) seam welding process Fig (4-19) Seam welding machine

B-welding side wall to top side rail (MIG WELDING)

MIG (Metal Inert Gas) welding, also known as MAG (Metal Active Gas) and in the
USA as GMAW (Gas Metal Arc Welding), is a welding process that is now widely used
for welding a variety of materials, ferrous and non-ferrous. Figure (4-20)
The essential feature of the process is the small diameter electrode wire, which is fed
continuously into the arc from a coil. As a result this process can produce quick and
neat welds over a wide range of joints. an electric arc forms between a consumable wire
electrode and the work piece metal(s), which heats the work piece metal(s), causing them
to melt, and join. Along with the wire electrode, a shielding gas feeds through the welding
gun, which shields the process from contaminants in the air. The process can be semi-
automatic or automatic

Figure (4-20) MIG machine

 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

4.6.1.2 Roof welding

A-welding steel panels to form the whole roof panel use tack welding as initial welding
then use seam welding

B-welding roof panel in place at the top of container see Figure (4-21)

Figure (4-21) Roof welding

 PROCESS SEQUANCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
4.7 Finishing and painting
4.7.1 Finishing

The final process is cleaning up the rust and Elimination of the scars which result from
the previous processes finishing process includes another blasting process to clean and
the whole container See Figure (4-22)

Figure (4-22) finishing and painting process

4.7.2 Painting
Painting the whole container (inside and outside) with the desired color See

Figure (4-23)

Figure (4-23) painting inside and outside of the container

 CHAPTER (5)
Manufacturing
processes
 CHAPTER (5) MANUFACTURING PROCESSES

‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

Phase (1) Sub Assembly.

1.1 Unrolling and cutting of steel sheets.
It all starts with sheet steel that arrives normally in coil form at a local steel
service center where it’s de-coiled into flat sheet, burr edge is slit away and the
sheet is cut to size as shown in figure (5-1)

Figure (5-1)

1.2 Shot blasting and priming of sheets.

First the steel is de-greased and shot blasted to Swedish standard SA 2.5 (near
white metal) as well as being primed with zinc rich primer as shown in
Figure (5-2). The steel used is often copper enriched (so called Corten A, a USS
trade name, or equivalent) This means that if the paintwork is penetrated by
damage, the exposed steelwork will react when oxidizing damage the exposed
steelwork will react when oxidizing in a way that inhibits
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
corrosion. Also a process takes place called ionic transfer
whereby the steel and zinc reacts to form a coating that assists durability
and results in an extended lifespan of the container

Figure (5-2)

1.3 Pressing.
After blasting and primer painting, the sheet steel undergoes pressing to form
front panels, side panels and roof sheets.
Pressing includes creating corrugation on the side panel sheets which helps
increase the strength of the container side walls

Figure (5-3)
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
1.4 Side panel sheets welded together and lashing rings added to top
side rail.

The separate side panel sheets are then welded together to form one complete
panel which fits the entire length of the container side wall.
Next a 60×60 RHS (rolled hollow section) top side rail has lashing rings added
and welded all round for strength. The side panel is then inverted on to the top
side rail and tack welded in position, followed by full welding. Side panel sub
assembly is now complete

Figure (5-4)

1.5 Container Front Wall.

{Front corner post, header, sill and front panel assembly}
The front corner posts are folded into shape. Front panels are then pressed,
ventilation holes are punched and two sheets joined together by seam welding.
Next the front header and bottom sill rail are prepared. These components are
assembled together in a jig with the addition of top and bottom corner castings.
Front panel assembly is now complete
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

Figure (5-5)

1.6 Container Rear Wall.

{Rear corner post, header, sill and rear panel (main cargo doors)
assembly}

Round pipe is cut to size, assembled with door cams at each end, door handle
saddles and power rings to aid anti-racking and galvanized to specification,
preferably hot dipped which is a better alternative than electrolysis Next the rear
corner post outer skins are punched and folded to shape, then welded to rear
corner post inners. Care must be taken to cater for distortion of the outer skin as
a lot of heat is generated during the welding process. This can otherwise affect
door hinge alignment. Rear header rails are then pressed and assembled
together with rear sills being prepared. Door panels are fabricated by adding
corrugations to flat sheet, ventilation holes are punched and installed within RHS
(rolled hollow section) vertical frames and “C” section members top and bottom,
often in a rotating frame to allow welding to be performed in the ideal downward
position.
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
The doors are then assembled together with the other rear end assembly
components detailed above together with corner castings, door hardware such as
cam keepers, galvanized hinge blades and lock boxes in a jig for full welding. The
rear end frame is now complete.

Figure (5-6)

1.7 Base frame preparation.

Next to prepare is the base frame. “C” section cross members are pressed, fork
pockets are fabricated in omega section profile, “C”
section bottom side rails are pressed and all parts are welded together in an
assembly jig

Figure (5-7)
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

1.8 Container Roof.

{Roof sheet die stamping and welding}

Roof sheets are stamped with a die that incorporates a pre-set camber to
facilitate drainage when containers are in use, it’s important to avoid water
pooling on the roof followed by freezing which would pose obvious dangers – for
example when trucks negotiate corners whilst the ice is thawing. The panel edges
are trimmed and sheets welded together to form the final sub assembly roofing
element.

Figure (5-8)
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
Phase (2) Main Assembly.
All six sub- assemblies transfer to the main assembly jig so that the
container can be put together. The base frame slides in first, next the
front and rear end frames followed by side walls and the entire
structure is tack welded together.

Figure (5-9)

The structure then travels down the production line for full welding
and attachment of roof sheets.

Figure (5-10)

Finally it now resembles the familiar shape of a

container
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
Secondary shot blasting then cleans all the areas damaged by the
welding processes. This is followed by the second phase of primer
painting as well as top coating and the container is then baked in an
oven.

Figure (5-11)

Figure (5-12)
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
Phase (3) finishing

Figure (5-13)

Paint touch up is common prior to loading floor sheets; sealant is

applied to the floor sheet peripheries which aids water-tightness in
that location.

Figure (5-14)
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
Next the floor sheets are drilled and secured using self-tapping screws.

Figure (5-15)

Then plastic ventilators are riveted into position over the ventilation
holes. Following this galvanized lock rods with bushes and retainers,
swivel customs catches and door handles are bolted on in compliance
with procedures required for approval of transportation under
customs seal.

Figure (5-16)
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬
CSC (Container Safety Convention) plates are then added to indicate all data
applicable as well as approvals granted to the container.
Next rubber gaskets with shot molded corners are installed with retaining strips,
the bottom edge and upright being filled with butyl sealant to inhibit corrosion
created if water were to become otherwise entrapped at this area. Markings are
then applied to comply with CSC (Container Safety Convention), UIC
(International Union of Railways) and ISO (International Standards
Organization) regulations covering intermodal freight containers.

Figure (5-17)

Next water testing checks for any pin holes that may have been missed
during light testing.

Figure (5-18)
 MANUFACTURING PROCESSES
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

Batch testing of the containers (normally one in fifty) ensures that

quality meets the construction standard required. Testing entails
stacking test, racking tests, sidewall strength test, front end wall
strength test, door strength test, roof test, floor test and maximum
gross weight testing, this is done to ensure that the container does not
bend beyond limits allowed when under full load (normally 30 tons
gross weight).

Figure (5-19)

Final inspection checks repair and touch up then

takes place in the outside container yard before
delivery for shipment.
 ‫‪Action Item Plan‬‬
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

‫‪Time‬‬

‫‪Code‬‬ ‫‪Activity‬‬
‫‪Sep‬‬ ‫‪Oct‬‬ ‫‪Nov‬‬ ‫‪Dec‬‬ ‫‪Jan.2015‬‬

‫‪1‬‬ ‫‪2‬‬ ‫‪3‬‬ ‫‪4‬‬ ‫‪1‬‬ ‫‪2‬‬ ‫‪3‬‬ ‫‪4‬‬ ‫‪1‬‬ ‫‪2‬‬ ‫‪3‬‬ ‫‪4‬‬ ‫‪1‬‬ ‫‪2‬‬ ‫‪3‬‬ ‫‪4‬‬ ‫‪1‬‬ ‫‪2‬‬ ‫‪3‬‬ ‫‪4‬‬

‫‪identify the‬‬
‫‪1‬‬ ‫‪project idea‬‬
‫‪(cargo‬‬
‫)‪containers‬‬

‫‪survey about‬‬
‫‪2‬‬
‫‪the cargo‬‬
‫‪containers‬‬

‫‪Prepare a visit‬‬
‫‪3‬‬
‫‪to factory 100‬‬

‫‪Studying the‬‬
‫‪4‬‬ ‫‪corrugation‬‬
‫)‪(roll bending‬‬
‫‪process‬‬

‫‪5‬‬ ‫‪Visit ICone‬‬

‫‪factory‬‬

‫‪Processes‬‬
‫‪analysis of‬‬
‫‪6‬‬ ‫‪container‬‬
‫‪manufacturing‬‬
 Time

Code Activity
Feb March may June July
April
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

7
divide the
container
into separate
components

8 Determined
the
requirements
of each
components
(tableau)

9 Model of
components
(solid work)

10 understood
the
constructions
of container

11 Model
assembly and
working
drawing
 CONCLUSION
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــ‬

We conclude from this Project that the various processes as applied

are dependent on various parameters. A good co-ordination is the key
to get best efficiency and high productivity.

 Each and every process depends on factors

such as the method used to carry out the
process, the type of the material used (whether
Aluminum,
 Mild Steel, Brass, etc.) And the thickness of
the material (or sheet).

 At the process of development of surfaces, the

allowances are to be increased as per the
thickness of metal.

The bending force on the job increases with broadness and thickness
of job but decreases with the length of die opening. In the technical
aspect, we conclude that nothing can be understood thoroughly
without practical knowledge and practice. We observed almost each
process related to sheet metal fabrication that we had just studied in
books. It was really a fruitful project for us to enhance our knowledge
and confidence level.
 Financial statements
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ‬

Financial statements:
If any organization interested in establishing containers factory , here
the final results of parallel project at industrial department named “
Feasibility study for cargo container “
Total cost ($) Rate of return of Payback period (year)
investment
48,651,382.11 % 21.39 3.67

This magnitude includes:

1- Materials Handling
2- Parts Machining
3- Welding lines
4- Painting lines
5- Finishing lines
6- Container Test Station
7- Auxiliary Equipment
8- Engineering Design
9- Transportation
10-Site Assembly
11-Training (including two years operation assistance)

Comparison between different ways to get a 20 ft cargo

container
importing cost ($ ) Factory Selling price
3000 2788

Note: for more information revise industrial

mechanical department, “Feasibility study for
cargo container “Graduation project 2015
 LIST OF REFRENCE
‫ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــــ ــــــــــــــــــــــــــــــ‬

References
[1] ISO Shipping Containers
[2] CIMC ISO dry container repairing spare parts catalog
[3] Jump up to: a b Levinson, Marc. "Sample Chapter for Levinson,
M.: The Box: How the Shipping Container Made the World Smaller
and the World Economy Bigger.". The Box: How the Shipping
Container Made the World Smaller and the World Economy Bigger.
Princeton University Press. Retrieved 17 February 2013.
[4] Jump up to: a b c d e f Lewandowski, Krzysztof (2014).
"Czechoslovak activity to prepare European norms for containers
before the Second World War" (PDF). Acta Logistica 1 (4): 1–7.
ISSN 1339-5629.
[5] "Brochure_Container_Packing" (PDF). hapag-lloyd. February 1,
2010. Retrieved 2014-05-30.
[6] Essery, R. J, Rowland. D. P. & Steel W. O. British Goods
Wagons from 1887 to the Present Day. Augustus M. Kelly
Publishers. New York USA. 1979 Page 92
[7] Cudahy, Brian J., "The Containership Revolution: Malcom
McLean's 1956 Innovation Goes Global". TR News. (c/o National
Academy of Sciences). Number 246. September–October 2006.
(Adobe Acrobat *.PDF document)
[8] LEVINSON (2006), The Box.
[9] GAVAN (container parts catalogue)
[10] WILLIAM COOK CAST PRODUCTS
[11] STEINECKER (TECHNICAL SPECIFICATION FOR STEEL DRY
CARGO CONTAINER 20’ x 8’ x 9’6” High Cube)
[12] D.N.V STANDARD FOR CERTIFICATION No. 2.7-1OFFSHORE
CONTAINERS -APRIL 2006

[13] HAPAG-LIOYD ( CONTAINER SPESIFICATION )

[14] CMA CGM CONTAINERS