IICL Container Inspector's Exam 2023 with complete solution questions and answers

Which of the following defects requires repair? A. A loose door gasket B. A bent J-bar that does not affect door operation C. A dent 13mm (1/2 in) deep on the door sill D. Four dents, each 11mm (7/16 in) deep, on contiguous outboard corrugations of a roof panel A. A loose door gasket Of the following conditions in a dry-van container, which one would require cleaning? A. Raised mud foot prints in excess of what might normally remain after a sweep out B. Dry dust covering dried floor stains as might normally be found after a sweep out C. Coffee beans remaining inside the container as might occur after a sweep out D. Polyurethane beads as might be expected to lodge in grooves between floorboards after a sweep out C. Coffee beans remaining inside the container as might occur after a sweep out An Equipment Interchange Receipt (EIR), based on an inspection with no damage found, can be evidence of a container's compliance with: A. Australian Timber Component Treatment Regulations B. Convention for Safe Containers (CSC) regulations through the ACEP Program C. Transport under custom's seal (TIR) regulations D. International Standards Organization (ISO) CEDEX codes regulations B. Convention for Safe Containers (CSC) regulations through the ACEP Program The top of a replacement plastic ventilator should be centered what distance from the top side rail? A. 50-55mm (2-2 3/16 in) B. 70-75mm (2 5/8 - 3 in) C. 100mm (4in) D. 150mm (6 in) A. 50-55mm (2-2 3/16 in) When must a reference line extend the full length of a bottom side rail? A. When there are two or more areas of damage on the bottom side rail B. When there is a sharp bend in the bottom side rail C. When there is a bowing over the entire bottom side rail D. When there is additional damage to the bottom side rail so that the reference line cannot be positioned over the ends of the damage C. When there is a bowing over the entire bottom side rail Which of the following is NOT a transverse structural member of the container? A. Front sill B. Tunnel rail C. Rear header D. Crossmember B. Tunnel rail A steel corner fitting is being replaced. To ensure better weld penetration, IICL recommends that the edges of parts adjacent to the corner fitting be ground to a minimum bevel of? A. 30 degrees B. 45 degrees C. 55 degrees D. 60 degrees B. 45 degrees Which of the following components is sometimes placed longitudinally in the container to support plywood flooring? A. Transverse bow B. Gusset C. Hat section center spacer D. Threshold plate C. Hat section center spacer Assuming owner and environmental regulations permit, which of the following procedures is NOT recommended for repairing tarpaulins or open top containers? A. Cleaning the area to be covered with acetone or mineral spirit B. Using a heat gun to fuse a patch to the tarpaulin C. Sewing on a patch of the same material as the tarpaulin D. Repairing a 6 mm (1/4 in ) pin hole with an epoxy compound C. Sewing on a patch of the same material as the tarpaulin Which of the following is an example of a plank floor condition requiring repair AND which should be considered as damage? A. A crack or split with no evidence of impact, which leaks light B. A crack or split with a sign of impact which does not leak light C. A crack or split, adjacent to a dented bottom rail, which leaks light D. A crack or split, with no evidence of impact, with a loose piece C. A crack or split, adjacent to a dented bottom rail, which leaks light Welds to corner fittings should be made with? A. CO2 semi-automatic welding B. Low hydrogen welding rods C. Fully automatic welding D. Arc welding B. Low hydrogen welding rods All of the following procedures are required EXCEPT A. Weld smoke, spatter, etc. must be removed to permit adhesion of paint B. The damaged component(s) must be restored as close as possible to original size and profile C. Welds must be examined using radiographic or magnetic particle non-destructive testing equipment D. Replacement steel components must be painted with coating compatible with that originally applied to the container C. Welds must be examined using radiographic or magnetic particle non-destructive testing equipment Where should the reference line be placed in order to determine repairworthiness of a crossmember flange that is bent upwards? A. Along the inside lower formed edge of the crossmember B. Spaced out from the crossmember web C. On the outermost flange surface along the full crossmember length D. No measurement is necessary D. No measurement is necessary The damaged top rail X below is to be repaired by sectioning. Care must be taken to ensure that damage area X is NOT cut less than a minimum of A. 50mm (2 in) B. 100mm (4 in) C. 150mm (6 in) D. 200mm (9 in) C. 150mm (6 in) Rework of previously straightened panels is required when A. evidence of considerable hammer marks is present B. the owner's policy requires repair C. the straightened area is an incorrect color D. original profile of the corrugation is changed B. the owner's policy requires repair Door gaskets that are cut may be repaired by using cyanoacrylate adhesives to bond together the cut edges of the gasket, PROVIDED (I) No gasket material is missing (II) The cut edges of the gasket mate together (III) The cyanoacrylate adhesive will fill voids that exist at the joint A. I only B. I and II only C. II and III only D. I, II and III (I) No gasket material is missing (II) The cut edges of the gasket mate together B. I and II only With wooden flooring, height variance between adjacent planks or panels is limited to A. 5 mm (3/16 in) B. 10 mm (3/8 in) C. 15 mm (9/16 in) D. 20 mm (3/4 in) A. 5 mm (3/16 in) In the Guide for Container Damage Measurement, IICL recommends a standardized procedure using set "reference dimensions" to determine if panel bows exceed ISO tolerances plus an additional IICL tolerance. The reference dimension for an outward bow in a side panel is A. 5 mm (3/16 in) B. 10 mm (3/8 in) C. 13 mm (1/2 in) D. 18 mm (11/16 in) D. 18 mm (11/16 in) Each of the following components has a single 30 mm (1 1/4 in) dent. Which one requires repair? A. Corner post B. Door panel C. Roof bow D. Bottom side rail A. Corner post For which of the following repairs does IICL recommend the use of pre-blasted steel? A. Sectioning of a tube-type top side rail 3 m (10 ft ) in length B. Replacement of a side panel 122 x 244 cm (4 x 8 ft) C. Inserting of a front corner post 182 cm (6 ft) in length on a high-cube container D. Full exterior container refurbishment B. Replacement of a side panel 122 x 244 cm (4 x 8 ft) When heat is used to straighten a corner post, the damaged area should be heated no more than A. 550 C (1022 F) B. 650 C (1200 F) C. 750 C (1300 F) D. 850 C (1560 F) B. 650 C (1200 F) Deflection Damage Criteria Deflection criteria are commonly used for damages such as dents or bows. This is the most common type of damage inspection criteria. It is based on setting a maximum dimensional limit on how far a component's surface can be permanently deflected from its original position. If the deflection is greater than the limit, repair is required. Envelope Damage Criteria Envelope damage criteria are commonly used for out-of-ISO and into-cube damages. Envelope damage criteria are based on allowing a component to deflect any amount provided the component stays within a reference plane or between a set of reference planes. The reference planes are usually planes that form an envelope on one or both sides of the component. The reference planes are often not physical surfaces on the container. Instead, they are virtual planes positioned in space a specified distance from physical surfaces on the container. When a component is permanently deflected beyond the reference plane, repair is required. All rails, including side rails, headers and sills // Repair if.... Holed, cut torn or cracked; broken component and/or weld // Missing or loose parts or fasterners Top side rails // Repair if Any deformation such as bend, bow, dent, etc.. Front and rear headers // Repair if Any deformation such as bend, bow, dent, etc (IF more than 35 mm (1-3/8 in) deep, EXCEPT on a header extension plate or corner protection plate Bottom side rails, front and door sills (Any deformation such as bend, bow, dent, etc. ON A WEB) // Repair if More than 50 mm (2 in) deep Bottom side rails, front and door sills (Any deformation such as bend, bow, dent, etc. ON A FLANGE) // Repair if torn, cracked or cut Door headers and sills // Repair if Interference with door closure, securement and/or not light-tight All corner posts, including j-bars // Repair if Holed, cut, torn or cracked; broken component and/or weld All corner posts, front and rear (Any single deformation such as bend, bow, dent, etc.) // Repair if more than 20 mm (13/16 in), regardless of length or location All corner posts, front and rear (OUTWARD deformation.) // Repair if more than 5 mm (3/16 in) beyond plane of end surfaces or 10 mm (3/8 in) beyond plane of side surfaces of corner fittings Rear corner posts // Repair if Any deformation causing interference with door operation, securement or light-tightness J-bars // Repair if Any deformation such as bend, bow, dent, etc. // Door must be able to open fully (270 degrees) All side/front panels // Repair if Holed, cut, torn or cracked; broken component and/or weld Missing or loose parts or fasteners INWARD deformation such as bend, dent, etc. (if more than 35 mm (1-3/8 in), measured on an exterior recessed corrugation) Side panels // Repair if OUTWARD deformation, such as bend, bow, dent, etc. (If more than 30 mm (1-3/16 in) measured on an inside recessed corrugation) Front panels // Repair if OUTWARD deformation, such as bend, bow, dent, etc. (If more than 15 mm (9/16 in) measured on an inside recessed corrugation) Ventilator covers // Repair if Broken, missing, etc. (If cracked or broken in the enclosed, baffled area of the ventilator) Door assembly, including hardware // Repair if Holed, cut, torn or cracked; browken component and/or weld Missing or loose parts or fasteners Any deformation such as bend, bow, dent, etc (If door operation or securement is impaired) Seized, frozen or stiff (If door operation or securement is impaired) Not light-tight Door panels // Repair if Any deformation such as bend, dent, etc (If internal cube intrusion is greater than 35 mm (1-3/8 in)) Door gaskets // Repair if Loose or missing Cut, torn, cracked or burned (If not light-tight or if the outer lips of the top horizontal gaskets are not fully in place and seated against the header) Roof panels, header extension plates, and corner protection plates // Repair if Holed, cut, torn or cracked; broken component and/or weld Corner protection plates and header extension plates // Repair if Any deformation such as bend, bow, dent, etc. (IF more than 40 mm (1-9/16 in) below top surfaces of top side rails) All roof panels (DOWNWARD) deformation such as bend, dent, etc. // Repair if IF more than 40 mm (1-9/16 in ) below top surfaces of top side rails All roof panels (UPWARD) deformation such as bend, dent, etc. // Repair if IF more than 40 mm (1-9/16 in ) above top surfaces of top side rails Floor and center rail // Repair if If light leaks, regardless of diameter or hole Broken component and/or weld; missing, loose or protruding fasteners Light leakage gaps between boards Wooden flooring // Repair if Delamination or splinters DOWNWARD deformation such as a bend or bow (IF more than 15 mm measured transversely at the floor screw center line) Wooden flooring (Gouges) // Repair if IF more than 15 mm (9/16 in) deep OR more than 5 mm (3/16 in) deep throughtout a width of more than 150 mm (6 in) of the gouge Wooden flooring (Different heights or surfaces) // Repair if IF difference is more than 5 mm (3/16 in) Plank flooring // Repair if Cracked or split (If light leaks) Anti-Rack Device Hardware normally attached to doors to provide additional strength and stiffness to the door and end frame assembly. Such a device allows containers to withstand greater transverse twisting (racking) forces Bend A deflection in a structural component which causes the component to change direction from that of its original design Blade Hinge component permanently attached by welding or bolting to the door Bottom Frame The lower structural support for the floor, panels and posts Bottom Side Rail A structural component running longitudinally along the bottom sides of a container between the end frames Bow A gradual (not abrupt) deformation of the entire length of the component in a direction perpendicular to the length Broken Fractured or shattered into two or more separate pieces Bushing A tubular enclosure surrounding a rotating shaft which reduces friction against rotation, and may reduce electrolytic corrosion Caulking (Sealant) Material used to seal all joints and riveted seams to ensure watertightness. Caulking is used between wood flooring and board edges, sides and end frame assembly Center Rail A steel section, found in many containers with plywood panel flooring, running along the center of the container from the rear sill to the front sill (or to the tunnel bolster) and separating the plywood panels along the longitudinal center line. This component often has a "hat-shaped" section, but a flat bar may also be used in some cases for the same center rail function Chassis A vehicle built specifically for the purpose of transporting a container, so that when the chassis and container are assembled, the unit produced serves the same function as a road trailer Consolidated Date Plate A single rectangular marking pate affixed to the door which containers certification information applicable to more than one convention, regulation or other certification Container A rectangular structure of standardized dimensions, designed to carry unit loads, packages or bulk cargo, and which is quickly transferable as a complete module between a number of modes of transportation. (Unless otherwise stated, this manual refers to "dry-van" or closed containers, whose cargo space is enclosed and weathertight when the container is carrying cargo.) Corner fitting (Corner casting) A steel component located at each of the container's eight corners (top and bottom) and welded to corner post and rail. The corner fitting (or corner casting) has apertures allowing the container to be handled, stacked and secured. Corner protection plate (corner gusset) An additional plate attached to the container roof, adjacent to the top corner fittings, providing protection from misuse of spreader equipment. Cracked Having a break which penetrates the entire thickness of material and causes it to split slightly. In addition, if a weld between two panels or two different metal components has any break in it, even if the entire thickness of the weld material is not penetrated, that weld is considered "cracked". Crossmember A transverse component, other than a sill, tunnel bolster or forklift pocket, attached to the bottom side rails and supporting the floor CSC (International Convention for Safe Containers, 1972) An international treaty which entered into force on September 6, 1977, requiring safety approval of all containers, the affixing of a safety approval plate ("CSC plate"), inspection at intervals thereafter, and maintenance in safe condition. The CSC is administered by individual governments with the advice of the International Maritime Organization (IMP), a branch of the United Nations. Cubic Capacity (Cube) Useable internal load-carrying space within a container, expressed in cubic feet, cubic meters (m3), gallons or liters. Also called "available cube" or simply "cube". Customs Plate A marking plate permanently affixed to the container which indicates compliance with the Customs Convention on Containers Customs Seal` A temporary device fitted to the container that prevents the container from being opened without detection Decal A self-adhesive, non-metallic marking permanently attached to the container Dent A localized depression in a panel or structural member made by pressure or an impact or blow that causes an abrupt change in the shape of a component over a limited area of the component Door Gasket (door seal) A piece of rubber or other flexible material attached to the door edges in order to provide a waterproof seal between the door and the end frame of the container. EIR An abbreviation for "Equipment Interchange Receipt." A document executed at the time of delivery, which attests to the interchange of a container, and which is normally signed by both parties. End Frame The components at either end of a container consisting of two corner posts, top and bottom corner fittings, header (top end rail) and sill (bottom end rail). The end frame components include the end frame plus the front wall and the doors, including all door hardware. Flange (bottom and top) A protruding edge used to strengthen a structural member by resisting tension or compression forces. The bottom flange is below the vertical portion (web) of the member and the top flange is above the web. Forklift pocket A special transverse component on the base structure of most 20ft and some 40ft containers enabling a forklift truck to insert tines in order to lift and handle the container. The forklift pocket is enclosed with a top plate, sides, and a bottom plate ("strap") at each end of the pocket entrance. It extends through the bottom rails, forming an open "pocket" inside the rails. Frame The peripheral structural assembly, including corner fittings, rails and/or posts, around one face of the container Gooseneck On a drop-frame chassis, the upper level of the front of the chassis, together with the structure connecting it to the lower level behind it. The gooseneck rails normally fit into a tunnel recess of containers so constructed. Gouge A cavity in the surface of flooring with material scooped out. The width of the gouge is the smaller horizontal direction, regardless of the orientation of the gouge Gusset Reinforcement plate normally welded in place Hazardous Cargo Labels Labels which are affixed to a container to warn of the presence of hazardous cargo inside during shipment. A list of required labels appears in the IMDG code. These labels are required by the IMDG code to be removed from a container after the cargo has been discharged. Holdback (tieback) Piece of hardware or nylon rope to hold door in the open position when loading or unloading ISO Abbreviation for the International Organization for Standardization, an international standards-writing body composed of national standards associations. Headquarters are in Geneva, Switzerland. Technical work is carried out by technical committees (TC's), such as ISO/TC104 (freight container committee). ISO Markings Markings placed on a container in conformance with ISO standards J-bar The portion of the outer post that extends from the rearmost edge of the rear portion of the corner post and that encircles the door hinges Keeper Locking bar cam retainer Lashing Fittings Cargo tie-down fittings for the attachment of straps or other devices to restrain movement of cargo Lining (dry van) Plywood or other material attached to the interior side and end walls and/or roof to protect the cargo Locking Bar (rod) The vertical shaft or rod to which the cam locks are fitted. When rotated, the cams may be locked in the cam retainer, forming an integral part of the door frame assembly Locking Bar Bracket A device attaching the locking bar to the top and bottom of a door, usually container a bushing Marking plates Durable plates which are permanently fixed to a container, upon which is contained certification or manufacturer's information Maximum Gross Weight (MGW) The sum, as certified by a classification society or manufacturer, of the tare (empty) weight (mass) of a container plus the maximum allowable weight (mass) of its contents (payload or cargo) Non-Repairworthy Damage or wear defects which do not have to be repaired because they are within all criteria limits specified in this Guide. Outrigger A short crossmember connecting the tunnel rail to the bottom side rail Payload (net weight) The total weight (mass) of the corgo or contents of the container, including removable cargo securement devices, dunnage, etc., but excluding the container and permanently installed fittings. It is also referred to as the net weight (mass) of the container. Pin (Hinge Pin) Hinge component attaching the hinge blade to the lug Plank A solid or longitudinally laminated hardwood or a softwood board Rain Gutter Part of, or attachment to, rear (door) header to divert water away from the door entrance TCT An abbreviation for Australian Timber Component Treatment, an immunization of exposed wooden components in compliance with Plant Quarantine requirements of the Australian Department of Health TIR (Transport International des Routiers) Road transport approval under regulation of customs authorities of different nations, allowing movement of goods across international frontiers, usually without opening containers in the process. In the USA, where TIR approval is not enforced, the initials TIR are often used interchangeably with EIR to refer to an interchange report Tunnel Bolster The crossmember supporting the rearmost portion of the gooseneck tunnel UIC (Union Internationale des Chemins de Per) Organization primarily of European railroads which establishes standards for container transport on member railroads Undercoating A waterproof material brushed or sprayed on the container underside. It protects the steel members from corrosion and waterproofs wooden flooring Ventilator A device permanently attached to the side (or front) panel of a container which allows the exchange of air between the interior and exterior of the container Ventilator Panel The portion of the side (or front) panel located behind the ventilator Web A metal sheet or plate connecting together the flanges of a structural member Straightening To mechanically or hydraulically restore a damaged component as close as possible to its original shape without removal of any portion of the component (although in certain cases adjacent components may have to be unfastened from the component being straightened) Welding To fuse two separated pieces of metal together using heat and a third piece of metal Inserting To restore a damaged component to its original size, shape and strength by cutting out a portion of the component that is less than the full-profile section and welding or fastening replacement material of the original size, shape and strength in place. The replacement part itself is called an insert Patching The same as inserting, except that the replacement material is slightly larger than the material being removed, and its edges overlap the parent material. The replacement itself is called a patch. (patching is only allowed for panels, and may substitute for inserting those components. For all other components, patching is not permitted unless otherwise stated in this manual) Sectioning To restore a damaged component to its original size, shape and strength by cutting out a portion of the component that extends through its full profile and welding or fastening replacement material of the original size, shape and strength in place. The replacement part itself is called a section Replacement To remove an entire damaged component and weld or attach a complete new component of the original size and strength. (In some cases, a different shape may be permitted) Dents to panels may be straightened without heating by using a jack; a flat hammer or mallet and backing plate Fractures, cracks, cuts or tears in a component or a weld joining components can be repaired by welding or a combination of straightening and welding; limitations: Maximum length of any crack fracture, cut or tear may be welded is 200mm (8 in) and the maximum width of separation is 5mm (3/16in) If the parent metal is unknown when welding up a crack use welding material with a minimum yield point of 46 kg/mm (65,000psi) Damage to steel components that cannot be repaired by straightening, welding or straightening and welding can, in many cases be repaired by installing an insert or, in the case of panels, an overlaying patch Inserts must be fitted flush with the existing component and should be fabricated to allow no more than 2 mm (5/64 in) clearance between adjoining surfaces Patches should overlap the existing panel on the exterior by 13 mm (1/2 in) Non-conforming repair is a condition resulting from a repair not being performed in accordance with IICL recommendations. Also called "improper repair" Corner fittings may be repaired ONLY by replacement All welds to corner fittings should be made with low-hydrogen welding rods or wire in order to minimize any chances of hydrogen embrittlement in the weld. (AWS E7016 and E7018 electrodes) Front corner posts (opposite from the door end) are shaped differently from the rear corner posts (at the door end) in order to maximize cubic capacity of the container and the width of the door opening A front corner post insert must be at least 150 mm (6 in) in length, unless it terminates at a corner fitting A front corner post insert that would terminate within 300 mm (12 in) of a corner fitting must be extended to the fitting, and must be at least 200 mm (12 in) in length For front corner post inserts there is no maximum height limitations (full-height front corner post inserts are acceptable) Inserting is not ________________ in the inner profile of a rear corner post permitted No insert in the outer profile section of a rear corner post can share the same horizontal plane as another insert If the type of material in the corner post is not known, the replacement steel must be high-tensile carbon or Corten steel of the same or greater thickness with a minimum yield point of 34 kg/mm or 50,000 psi Back-up plate are temporary fittings on which an insert in a tube-type rail can be rested to ensure easy and accurate positioning of the insert as it is continuously welded into place Before cutting out the rail support the container so that it does not distort when the rail section is cut out When cutting out the damage the cut should extend beyond the damaged area to allow insertion of wedges between top rail and roof panel Side and front panels are the thinnest components of the container, yet they must be able to withstand forces of 60% and 40% of payload, respectively Container roofs are made of either self-supporting corrugated panels or flat panels supported by roof bows Roof panel insert, patch and replacement material should be of Corten steel unless the original material is known to be different and the owner consents to use other material. If corten steel is not used, use 2 mm (14 gauge) thick replacement material Holes or cuts in tarpaulins may be patched unless it would be less expensive to replace the tarpaulin and/or the owner requires replacement for other reasons ____________________ repair a tarpaulin by sewing on a patch. Do not (understructure) When installing screws in a replacement understructure component, use zinc-plated or other similarly treated self-tapping screws with the same diameter of screw head and shank as the original Sections through the complete profile of the C-channel forklift pocket side are not permitted When repairing flooring, the method of repair should be the least aggressive necessary to correct the damage. The general order of aggressiveness, from least to most, is: -Cleaning -Dowel repair -Sectioning or partial replacement -Complete replacement of floor The use of _______________________________ is not recommended by IICL as a method of repair for wooden floor repairs. wood filler Sealant exposed to cargo-carrying surfaces should not be of butyl material, but rather of urethane or chloroprene material suitable for contact with cargo Methods of cleaning flooring (increasing in aggressiveness) Sweeping Washing with water Washing with detergent steam cleaning sanding Holes up to ___________________ in diameter may be repaired by inserting a round hardwood dowel into the hole and securing it into place with glue. 13 mm (1/2 in) Replacement planks and plywood boards, as well as undamaged remaining planks or boards, must cover __________________________________________________________________________. at least three crossmembers or forklift pocket sides Because the interior surfaces of doors may be exposed to weather when the doors are open, door repairs on the interior side should be_________________________________________ top coated as well as primed Free hinge pins by lubricating the hinge with penetrating oil A container ventilator consists of a plastic or steel cover approximately 25 mm (1 in) in depth which is fitted over an area of the container side panel in which holes have been drilled The inside of the cover (ventilator) is fitted with horizontal projections called _______________ to permit air interchange while preventing the entrance of water. baffles