TOP RAILS - Continued
Replacement Sectioning or Full Length Replacement.
When installing a replacement section, the entire cross section of the rail must be removed. The
following limitations apply:
No more than 2 full-profile vertical welds are permitted in a 20-foot rail.
The limitations above do not include the weld connections between rail and corner fittings or
other welds performed as part of original manufacture.
Replacement material must be of the same specification, gauge and profile as the original.
Sections must be at least 6 in (150 mm) in length.
If a section in a top side rail would end within 12 in (300 mm) of a corner fitting, it must be
extended to the fitting.
If a section would end within 6 in (150 mm) of an existing vertical weld, it must be extended
to that weld.
If the damage extends over a distance equivalent to 50% or more of the container length, the
complete rail must be replaced.
(1) Determine the length of original rail (1) to be removed. Mark where the cuts are to be made.
(2) Remove any foam, lining and/or other parts which block access to the repair area.
(3) Remove fasteners (2) attaching top rail (1) to end frame brackets (5) (if section extends to the corner
fitting), side posts, side panels, roof and roof bows as appropriate.
(4) Separate side panel (4) and top rail (1) with wedges no more than 3/32 in (4 mm) thick.
(5) Use a disc cutter to free the damaged part of the rail.
(6) Straighten the remaining rail edges if bent and grind all areas smooth.
(7) Remove any old barrier tape.
(8) Cut to size, clean and fit replacement section or new rail into position. The section must fit flush with
the remaining rail profile. Allow no more than 5/64 in (2 mm) clearance between adjoining edges. If
the roof or side panels are made of aluminum, prepaint and apply new barrier tape to prevent
(9) Position new rail or section and tack weld into place. Check alignment to ensure that ISO dimensional
tolerances are maintained.
(10) Continuously weld the replacement section or new rail in place.