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集装箱维修与检验IICL国际标准深圳南方中集集装箱服务有限公司2005年9月1目录第一章集装箱结构············································································2第一节简介················································································2第二节集装箱结构专用术语···························································2第二章集装箱检验···········································································12第一节检验的一般要求································································12第二节缺陷的种类······································································13第三节集装箱检验标准································································18第三章集装箱损坏的测量··································································26第一节测量损坏的基本方法··························································27第四章集装箱清洁···········································································37第一节概述···············································································37第二节清洁方法·········································································38第五章翻新及表面处理·····································································43第一节翻新之前的检验································································44第二节打砂之前的准备·······························································44第三节表面预处理······································································46第四节底漆的喷涂······································································48第五节重新安装标志物与构件·······················································49第六章钢制集装箱的修理··································································51第一节概述···············································································51第二节角件的修理······································································52第三节角柱的修理······································································53第四节箱梁构件的修理································································58第五节侧板与前端板的修理··························································63第六节箱顶的修理······································································66第七节底架的修理······································································69第八节地板的修理······································································79第九节箱门的修理······································································85第十节通风器的修理···································································922第一章集装箱结构第一节简介从事集装箱检验或修理工作的人员，首先必须掌握有关集装箱结构设计特征方面的基本知识，为适应集装箱装运货物及在不同运输模式间快速转换的需要，集装箱在尺寸及结构特征上已实现了标准化。集装箱有封闭型的杂货箱、敞顶箱、高容积、敞侧箱、板架箱、罐式箱、冷藏箱等多种类型，这些具有不同特点的集装箱能分别适应不同的装货要求。集装箱最常见的长度规格有20英尺与40英尺两种，国际标准化组织出版的有关标准中列有这些尺寸规格。第二节集装箱结构专用术语1、结构术语集装箱各部分构件在世界不同地区各有不同的名称和叫法，但某些名称与叫法却已得到广泛采纳，成了这一项领域内的习惯用语，其中较为重要的有：后端：所谓“后”，指的是朝箱门一端的方向，后端为集装箱上开有箱门的这一端，又称门端；前端：指集装箱上与门端相对的那一端；左侧：指身处箱外且面朝集装箱门一端时所见到的集装箱左侧；右侧：指身处外且面朝集装箱箱门一端时所见到的集装箱右铡；角柱：竖立在集装箱前、后两个端框这角部位的结构件；角件：安装在集装箱八个箱角部位，与角柱及上、下箱梁焊接在一起的钢制构件。角件上有孔，对集装箱的装运、堆码及栓固作业正是凭据角件上的孔才得以实施的；端框：在集装箱任一端的箱框，由两根角柱、两个上角件、两个下角件、上端梁和下端梁组成。前端的端框称为前框，前框部件中还包括前端壁；而后端端框又称后框或门框，门框部件中则包括箱门及箱门上的所有附件；底架：支承地板、箱壁板及角柱的箱底框架；3鹅颈槽：集装箱底架中的凹槽结构，用来与配有鹅颈构造的运输集装箱专用底盘车相配合。正常运行时，底盘车上的鹅颈梁是白插入与之配套的集装箱鹅颈槽当中的；叉槽：集装箱底架上的特殊横向结构件。叉车的叉齿能插入到集装箱的叉槽内，将集装箱提升起来运走；上侧梁：沿箱顶侧面纵向排列且连接前、后两个端框的结构件；底横梁：除前槛、后槛、鹅颈槽主横梁、叉槽侧梁之外，安装于下侧梁上用来支承地板的横抽构件；腹板：箱体结构上连接上、下两个凸缘的中间部分钢板；支梁：焊接在鹅颈槽侧梁与下侧梁之间的短底横梁；鹅颈槽主横梁：支承鹅颈槽后部的大横梁；鹅颈槽侧梁：位于鹅颈槽上凹槽两边、支承鹅颈槽盖板的纵梁；鹅颈槽盖板：将集装箱箱内空间与鹅颈槽上凹槽分割开来的钢板；地板中梁：在安装胶合木地板的集装箱中常可以见到这种型钢；该件从门槛到前槛（或到鹅颈槽主横梁）分布在集装箱中央，沿纵向中线将地板划分为两部分。型钢多为帽状结构，但在某些集装箱中也有用平型梁来作中梁的；捆绑附件：集装箱上捆绑货物用的附件，用于系缚绳索或安装其它系缚装置以阻止箱内货物移动；箱楣：即上端梁，是端框上连接左、右两个上角件的横向构件。前框上的箱楣称为前楣，后框上的箱楣称为后楣或门楣；楣部延伸板：前楣或后楣上超出左、右两个上角件无孔壁横向连线的那部分钢板，其作用是保护箱项使其免遭破坏；前槛与后槛：箱槛即下端梁，前端框中连接左、右下角件的横梁称为前槛；后端框中的连接左、右下角件的横梁称为后槛或门槛；抗变形装置：安装在箱门上对箱门及门框以增加强度与刚性的金属构件。集装箱配上这种装置后能经受更大的横向扭力；J形柱：从门端内角柱的后端边缘起朝后延伸并包绕门铰链的那部分外角柱；锁杆：两端设有锁头的竖轴，旋转时锁头会转入锁座，成为门框组合件上的一个组成部分；4锁杆支架：将锁杆固定于箱门的装置，其内常装有衬套；锁杆夹：安装在两个锁杆支架当中的锁杆夹持件，使锁杆在箱门上处于适当的位置；锁头：箱门锁杆的一部分，通过凸轮杠杆原理与锁座配合，形成门锁；锁座：当箱门锁紧时，夹持住锁头的构件；门把手：装在锁杆上用来转动锁杆的附件，用来开关并锁紧箱门；门把托架：将门把手托持于闭合状态的装置。托架上面还有一个可转动的托架盖，可将门把手锁定于闭合位置；门封条：装在箱门边缘部位的橡胶条，使箱门与门框之间密不透水；门封压条：装在门框上用来压紧门封条的镀锌钢条或铝条；海关门扣：一种固装于箱体上以确保只有当右箱门打开后左箱门才能被打开的装置；海关关封：一种临时性装在集装箱上，用来确保该集装箱箱门不能不留痕迹地被打开的装置；TIR绳索：一种由海关当局指定的绳索，用来将敞顶箱箱罩固定在箱顶上以保护货物。防雨箱罩上的圆孔套上TIR绳环后，用该绳穿过各个TIR绳环，固紧后施以关封；TIR绳环：焊装在敞顶箱侧梁上的圆环，使得防雨箱罩能紧紧罩在敞顶箱顶部；接水盘：敞顶箱上一种钢制装置，安装在箱内各角上方，当装上防雨箱罩时，该装置起到密封的作用；标贴：一种本身具有粘性、用于永久性粘贴于集装箱表面的标志；铭牌：一块固定在箱门上的矩形牌，上面标有一种以上公约、规则等证书的信息；通风器：永久性安装在集装箱侧板上的一种装置，能使箱体内外的空气流通；2、结构特征集装箱一般由钢质刚性框架以及各框架之间的箱壁板所组成。图1-1所示的是一个40英尺集装箱的总体布置图。从图中可以看到，在集装箱当中，框架是主要的承载部分。箱体框架由前端框、门框、纵向排列的上侧梁与下侧梁以5及横向排列的底横梁等组合而成。在许多40英尺箱（也包括一些40英尺箱）的底架结构中，有一种便于叉车搬运的特殊横向部件—叉槽，见图1-2。叉槽由一块顶板、两块侧板以及叉槽两个槽口处的底板所构成。此外，有许多40英尺集装箱的底架上还有一个鹅颈槽结构。如图1-3所示，该结构为一个上凹槽，槽上有一块盖板，由前槛向后沿展。鹅颈槽后端由一根鹅颈槽主横梁支撑，而两侧又各有一根鹅颈槽侧梁承载。鹅颈槽区域的底横梁较短，名为支梁，它们分布在左、右下侧梁与各鹅顶槽侧梁之间。6图1-17在前端框架当中的是一道由端板拼焊而成的端壁。而在上、下侧梁之间的则是由各侧板拼合而成的集装箱侧壁。有些集装箱的波纹型侧板在靠近前、后图1-2图1-38端处各有一个自上而下一通到底的平面区，称为标志面，专用于贴置箱主规定的标志；有些集装箱的上侧梁下方侧壁上装有通风器。使得集装箱内外空气能够循球流通，并能阻挡固态或液态异物从箱外进入箱内。在杂货箱的两根上侧梁之间是用平型或波纹型钢板拼接而成的箱顶板。如采用平型钢板平顶板，则需要在箱内顶部装上一定数量的箱顶拱梁进行支撑。顶板一般在中部具有向上的长度，以防止箱顶部位积水。在箱顶靠近角件的部位，可安装一块箱角加强板（顶角护板）来增加强度另外，也可以采用楣部延伸板来提高箱顶的强度。货物是堆放在集装箱内的地板上的。地板分别由两根下侧梁、前槛、门槛以及许多底横梁（有时还包包括叉