Centre Equipment & EMR – March 2014

Guidelines to..
Plywood Floor Repairs

This document shall be used by EMR teams and EMR

vendors as an update to MCIC v6, Section 6 “Repairs
to Plywood Floors”, describing what are the
acceptable repairs in all cases.

Document Reference: CENEMR/2014/002/MRS046

Contents

• Floorboard Specifications

• Floorboard Types

• General Repair Guidelines

• Floorboard Damage/Repair Cases

• STS Codes Summary

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

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

bamboo.
• Overall floorboard thickness is 28 mm (min. 19 plies).
• Plywood species that be used include: Eucalyptus, Poplar, Birch, Beech,
Pine, Larch, etc.
• Maximum moisture content shall not exceed 14%.
• Outer three plies on each side are made of Apitong or Keruing.
• Wood is chemically treated according to the requirements of the
Commonwealth of Australia, Department of Health, Australian Quarantine
and Inspection Service (AQIS) [Timber Components Treated – TCT
Certificate].
• Plywood floors shall be FSC certified (Forest Stewardship Council).
• Floorboard shall pass the following tests:

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

Floor Panels – IICL TB001).

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

• Boiling Test (GB/T 19536 – 2004).

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

Floorboard Types (Can be sporadically found in Maersk Line container fleet)
General Repair Guidelines
• Delaminated floorboard is defined as: damage observed down to the 4 th ply layer (e.g. top 3 plies are missing + min. 1
loose ply).

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

• Floorboards over the outriggers in 40ft containers shall also be repaired using full width replacements. Standard width
for those boards is 636 mm.

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

• Steel patches are never acceptable as a permanent method of repairing. Holed floorboards should be repaired by dowels
(up to 25 mm hole diameter) or replaced when observed, according to the cases found in this document.

• Floorboard with finger cracks shall be repaired, only if one of the following conditions is fulfilled: visible sign of impact on
the opposite side – damage to an adjacent component (rail, cross member, etc.) – visible bowing on the floor’s opposite
side – hollow sound when affected floor is tested by hammer. If repair-worthy, follow the guidelines in this document.

• Full board replacement (1160x2400 mm) [Case 9] is not a requirement unless the damage is covering over 75% of the
board area. If less, there are different codes with dimensions to choose from according to [Case 8].

• If the damage is not described in this document, apply common sense. As a rule of thumb, replaced board should cover
at least 3 support members (cross member, outrigger, tunnel bolster, sill or FLP cross member). Furthermore, original
(undamaged) floorboard should also cover at least 3 support members after the repair is made. If damage is within the
edge of a floorboard, repair should be extended to this edge.
Floorboard Damage Cases
Floorboard Damage Cases
Case 1
Size Design Damage Location

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

DAMAGE REPAIR

Repair Dimensions STS Code Repair Name

(W*L) mm
Full board replacement 1160*1000 6525 Replace Plywood Section 1160x1000mm
(Case 1/3/8)
Floorboard Damage Cases
Case 2
Size Design Damage Location

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

DAMAGE REPAIR

Repair Dimensions STS Code Repair Name

(W*L) mm
Partial replacement: extended door 1160*1300 6523 Replace Plywood Section 1160x1300mm
sill + min. 4 cross members (Case 2/8)
Floorboard Damage Cases
Case 3
Size Design Damage Location

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

DAMAGE REPAIR

Repair Dimensions STS Code Repair Name

(W*L) mm
Full board replacement 1160*1000 6525 Replace Plywood Section 1160x1000mm
(Case 1/3/8)
Floorboard Damage Cases
Case 4
Size Design Damage Location

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

DAMAGE REPAIR

Repair Dimensions STS Code Repair Name

(W*L) mm
Partial replacement: front sill + 1160*650 6521 Replace Plywood Section 1160x650mm
min. 2 cross members (Case 4/5/6/8)
Floorboard Damage Cases
Case 5
Size Design Damage Location

20ft. Any design Floorboard above or adjacent to the forklift

pocket (FLP)

DAMAGE REPAIR

1 FLP Cross Member + 2 FLP Cross Members +

2 normal Cross Members 1 normal Cross Member

Repair Dimensions STS Code Repair Name

(W*L) mm
Partial replacement: total covering 1160*650 6521 Replace Plywood Section 1160x650mm
3 cross members. (Case 4/5/6/8)
Floorboard Damage Cases
Case 6
Size Design Damage Location

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

DAMAGE REPAIR

Repair Dimensions STS Code Repair Name

(W*L) mm
Partial replacement: area covering 1160*650 6521 Replace Plywood Section 1160x650mm
bolster + min. 2 cross members (Case 4/6/8)
Floorboard Damage Cases
Case 7
Size Design Damage Location

40ft. Any design Small floorboard over the outriggers.

DAMAGE REPAIR

Repair Dimensions STS Code Repair Name

(W*L) mm
Partial replacement: area covering 636*750 6520 Replace Small Plywood Section
3 support members: (bolster + 636x750mm (Case 7)
min. 2 cross members) 636*1600 6522 Replace Small Plywood Section
OR (min. 3 cross members) 636x1500mm (Case 7)
Floorboard Damage Cases
Case 8
Size Design Damage Location

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

DAMAGE REPAIR

Repair Dimensions STS Code Repair Name

(W*L) mm
Partial replacement: area covering 1160*650
1160*800
6521
6526
Replace
Replace
Plywood Section
Plywood Section
1160x650mm (Case 8)
1160x800mm (Case 8)
min. 3 cross members 1160*1000
1160*1300
6525
6523
Replace
Replace
Plywood Section
Plywood Section
1160x1000mm (Case 8)
1160x1300mm (Case 8)
1160*1600 6527 Replace Plywood Section 1160x1600mm (Case 8)
1160*1900 6528 Replace Plywood Section 1160x1900mm (Case 8)
1160*2100 6529 Replace Plywood Section 1160x2100mm (Case 8)
Floorboard Damage Cases
Case 9
Size Design Damage Location

Any Any design Similar to Case 8 but bigger damage area,

beyond 75% of panel area.

DAMAGE REPAIR

Repair Dimensions STS Code Repair Name

(W*L) mm
Full floor panel replacement. 1160*2400 6524 Replace Full Plywood Panel
1160x2400mm - Case 9
Summary of STS Codes
STS Repair Name Status Case(s) Qty. Time
Code Pcs. per pc.
6520 Replace Small Plywood Section 636x750mm New 7 4 0.5 hr.

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

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

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

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

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

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

6527 Replace Plywood Section 1160x1600mm New 8 4 1.7 hr.

6528 Replace Plywood Section 1160x1900mm New 8 2 1.9 hr.

6529 Replace Plywood Section 1160x2100mm New 8 2 2.0 hr.

Improper Repairs
Workmanship Material

Gap should be max. Wrong location of screws Wrong material used! Poor floorboard quality.
1mm. – or wrong size of
plywood, resulting in
Screw head should be failure to secure the
min. 16mm. floorboard from one edge.

Workmanship/Quality issues should be

highlighted during the audits or the normal visits
to the vendors (post-repair / previous-repair
inspection). Raw material inspection should also
be done during the audit and more importantly,
shall be monitored by the vendors themselves.