Engineering Design Handbook - Packaging and Pack Engineering

391 Pages·23.823 MB·391\391

AMC PAMPHLET AMCP 706-121
ENGINEERING DESIGN
HANDBOOK
PACKAGING AND PACK
ENGINEERING
HEADQUARTERS, U.S. ARMY MATERIEL COMMAND MARCH 1972
AMCP 706-121
PREFACE
This handbook is one of a series covering engineering principles and fundamental data
needed in the development of Army materiel, which (as a group) constitutes the
Engineering Design Handbook Series of the Army Materiel Command. The handbook is a
revision of the one published in 1964.
Included in this handbook are the fundamental principles, policies, and limitations of
military packaging and pack engineering. Also included is information concerning basic
causes of deterioration, methods of preservation, types of preservatives and packaging
materials available, natural and transportation environment encountered, cost and human
engineering factors, distribution system limitations, and other special military packaging
considerations. All chapters of the handbook have been revised and updated to include
the latest packaging engineering developments. Three new chapters have been added in
the areas of exterior protection, marking, and testing and inspection. Design parameters
for military packaging differ importantly from those required for commercial efforts. The
primary intention of this handbook is to serve as an introduction to military packaging
and pack engineering. A major portion of the text is devoted to a broad treatment of the
subject, emphasizing the why of military packaging and directing the user to other
authoritative publications for information on how to perform specific engineering tasks.
This handbook was revised by Ryco Engineering Incorporated,' Warren, Mich., under
subcontract to the Engineering Handbook Office of Duke University, prime contractor to
the U.S. Army for the Engineering Design Handbook Series. Technical guidance and
general assistance were provided by an Ad HOC Working Group as follows: Clair L.
McDermit, Chairman, U.S. Army Tank-Automotive Command; Joseph V. Budelman, U.S.
Army Aviation Systems Command; Frank J. DePalma, U.S. Army Electronics Command;
Herbert W. Maas, Jr., U.S. Army Mobility Equipment Research and Development Center,
Joseph P. Akrep, U.S. Army Natick Laboratories; Howard Weiner, U.S. Army Munitions
Command; Arnold W. Voss, Tobyhanna Army Depot; and Samuel A. McFate, U.S. Army
Weapons Commnad.
The Engineering Design Handbooks fall into two basic categories, those approved for
release and sale, and those classified for security reasons. The Army Materiel Command
policy is to release these Engineering Design Handbooks to other DOD activities and their
contractors and other Government agencies in accordance with current Army Regulation
70-31, dated 9 September 1966. It will be noted that the majority of these Handbooks
can be obtained from the National Technical Information Service (NTIS). Procedures for
acquiring these Handbooks follow:
'William Dolunt, Project Engineer, Paul Sandor and Joseph Nerone, Technical Writers
xx
AMCP 706-121
a. Activities within AMC, DOD agencies, and Government agencies other than DOD
having need for the Handbooks should direct their request on an official form to:
Commanding Officer
Letterkenny Army Depot
ATTN: AMXLE-ATD
Chambersburg, Pennsylvania 17201
b. Contractors and universities must forward their requests to:
National Technical Information Service
Department of Commerce
Springfield, Virginia 22 15 1
(Requests for classified documents must be sent, with appropriate “Need to Know”
justification, to Letterkenny Army Depot.)
Comments and suggestions on this Handbook are welcome and should be addressed to:
U. S. Army Materiel Command
ATTN: AMCRD-TV
Washington, D. C. 203 15
xxi
HEADQUARTERS
UNITED STATES ARMY MATERIEL COMMAND
WASHINGTON, DC 20315
AMC PAMPHLET 13 March 1972
NO. 706-121*
ENGINEERING DESIGN HANDBOOK
PACKAGING AND PACK ENGINEERING
Paragraph Page
LIST OF ILLUSTRATIONS ............ ............................ xii
LIST OF TABLES .................................................. xv 1
PREFACE ......................................................... XX
CHAPTER 1
INTRODUCTION TO MILITARY PACKAGING
1-1 MILITARY PACKAGING POLICY ................................. 1-1
1-1.1 PURPOSE ....................................................... 1-1
1-1.2 OBJECTIVES ..................................................... 1-1
1-1.3 DEFINITIONS .................................................. 1-1
1-1.4 METHODS OF EXPRESSING PACKAGING DATA ................. 1-1
1-2 ROLE OF THE PACKAGING ENGINEER ........................... 1-2
1-3 PACKAGING AND PACKING METHODS .......................... 1-2
1-3.1 CRITERIA TO BE CONSIDERED ................................. 1-2
1-3.2 PROTECTION LEVELS .......................................... 1-3
1-4 MILITARY vs COMMERCIAL PACKAGING ........................ 1-5
....................................................
REFERENCES 1-5'
BIBLIOGRAPHY .................................................. 1-5
CHAPTER 2
FUNDAMENTALS OF PACKAGING DESIGN
2- 1 PACKAGING ENGINEERING PRINCIPLES ......................... 2- 1
2-2 PACKAGING ENGINEERING PROCEDURES ....................... 2- 1
2-3 SOURCES OF DATA .............................................. 2- 1
2-4 ITEM CHARACTERISTICS ......................................... 2- 1
2-4.1 SUSCEPTIBILITY TO CHEMICAL DETERIORATION AND PHYSICAL
DAMAGE ...................................................... 2-2
2-4.2 FEASIBILITY OF DISASSEMBLY .................................. 2-2
2-4.3 OTHER ITEM CHARACTERISTICS ............................... 2-2
2-5 ADDITIONAL FACTORS AFFECTING PACKAGING DESIGN ....... 2-2
2-6 LOGISTICAL CONSIDERATIONS .................................. 2-3
2-6.1 TRANSPORTATION ............................................. 2-3
2-6.2 HANDLING .................................................... 2-4
2-6.3 STORAGE ...................................................... 2-4
2-6.4 HUMAN FACTORS CONSIDERATIONS ........................... 2-4
2-6.5 WEIGHT AND CUBE ............................................ 2-4
2-6.6 DISTRIBUTION ................................................. 2-4
2-6.6.1 Pattern ........................................................ 2-4
*This pamphlet supersedes AivEcP 706-121, 30 October 1964.
AMCP 706-121
TABLE OF CONTENTS (Continued)
Paragraph Page
2-6.6.2 Unit Quantity .................................................. 2-4
2-6.7 DESTINATION .................................................. 2-4
.....................................
2-6.8 STATUTORY LIMITATIONS 2-8
2-7 PACKAGING, PACKING, AND SHIPPING COSTS ................... 2-8
2-8 TESTING AND INSPECTION ...................................... 2-8
2-9 AUTHORIZED AND APPROVED METHODS AND MATERIALS ...... 2-9
2-9.1 SPECIAL REQUIREMENTS ...................................... 2-9
..............................
2-9.2 NEW METHODS AND MATERIALS 2-9
2-10 SUMMARY OF PACKAGING AND PACK DESIGN .................. 2-9
REFERENCES .................................................... 2-1 1
BIBLIOGRAPHY .................................................. 2-12
CHAPTER 3
ITEM CHARACTERISTICS
......................................................
3-1 LIKE ITEMS 3- 1
.........................
3-2 STANDARD AND NONSTANDARD ITEMS 3-1
3-2.1 STANDARD GROUP ITEMS ..................................... 3- 1
3-2.2 NONSTANDARD GROUP ITEMS ................................. 3- 1
....................................
3-3 PACKAGING REQUIREMENTS 3-2
........................
3-4 CATEGORIZING ITEM CHARACTERISTICS 3-2
3-4.1 OBJECTIVES .................................................... 3-2
........................
3-4.2 PRE-ENGINEERING PACKAGING DATA 3-2
3-4.3 MINIMUM CRITERIA ............................................ 3-4
............................
3-4.3.1 Vulnerability to Chemical Deterioration 3-4
3-4.3.2 Vulnerability to Physical Damage .................................. 3-4
.......................................................
3-4.3.2.1 Shock 3-4
3-4.3.2.2 Vibration .................................................... 3-6
................................................
3-4.3.2.3 Surface Finish 3-6
.............................................
3-4.3.2.4 Degree of Hazard 3-9
3-4.3.3 Strength and Fragility ...................................... .: ... 3-9
3-4.3.3.1 Fragile, Delicate, and Rugged Items .............................. 3-9
.......................................
3-4.3.3.2 Flexible and Rigid Items 3-10
..................................................
3-4.3.4 Type of Load 3-1 1
3-4.3.5 Configuration .................................................. 3-1 1
................................................
3-4.3.6 Size and Weight 3-1 1
.........................................................
3-4.3.6.1 Size 3-1 1
......................................................
3-4.3.6.2 Weight 3-1 1
3-4.3.7 Nature of the Item .............................................. 3-1 1
................................
3-4.3.8 Relation of Item Design to Package 3-13
3-4.3.9 Compatibility of Materials ........................................ 3-13
...................................................
3-4.3.10 Cost of Item 3-14
REFERENCES .................................................... 3-15
ii
AMCP 706-121
TABLE OF CONTENTS (Continued)
Paragraph Page
CHAPTER 4
DETERIORATION
4- 1 DETERIORATION OF METAL ..................................... 4-1
.....................................................
4-1.1 MOISTURE 4-1
4-1.2 CHEMICAL ACTION ............................................ 4-1
4-1.2.1 salts .......................................................... 4-1
4- 1.2.2 Acids and Alkalies .............................................. 4-1
4-1.3 ELECTROCHEMICAL ACTION ................................... 4-2
..........................................
4-1.4 LOW TEMPERATURES 4-6
4-1.5 CORROSION PREVENTION ...................................... 4-6
.................................................
4-1.5.1 Metal Coatings 4-7
..........................................................
41.5.2 Paint 4-7
.................................
4-1.5.3 Semipermanent Surface Treatment 4-7
4-2 DETERIORATION OF WOOD ...................................... 4-9
............................................
4-2.1 MICRO-ORGANISMS 4-10
........................................................
4-2.2 INSECTS 4-10
.............................................
4-2.3 PHYSICAL AGENTS 4-10
............................................
4-2.4 CHEMICAL ACTION 411
..........................
4-3 DETERIORATION OF PAPER PRODUCTS 411
.....................................................
4-3.1 MOISTURE 4-11
............................................
4-3.2 MICRO-ORGANISMS 4-11
........................................................
4-3.3 INSECTS 4-11
......................................................
4-3.4 RODENTS 4-13
.....................................................
4-3.5 SUNLIGHT 4-13
.........................................
4-3.6 HIGH TEMPERATURES 4-15
....................................................
4-3.7 CHEMICALS 4-15
...................................
4-4 DETERIORATION OF PLASTICS 4-15
....................................................
4-4.1 CHEMICALS 4-15
............................................
4-4.2 MICRO-ORGANISMS 4-15
..........................................
4-4.3 LOW TEMPERATURES 4-15
4-5 DETERIORATION OF RUBBER .................................... 4-17
....................................................
4-5.1 CHEMICALS 4-17
.......................................
4-5.2 TEMPERATURE EFFECTS 4-18
............................................
4-5.3 MICRO-ORGANISMS 4-18
.....................................................
4-5.4 SUNLIGHT 4-20
4-6 DETERIORATION OF TEXTILES .................................. 4-20
............................................
4-6.1 MICRO-ORGANISMS 4-20
4-6.2 EXCESSIVE DRYING ............................................ 4-21
46.3 SUNLIGHT ..................................................... 421
....................................................
REFERENCES 4-34
..................................................
BIBLIOGRAPHY 4-34
iii
AMCP 706-121
TABLE OF CONTENTS (Continued)
Paragraph Page
CHAPTER 5
CLEANING AND DRYING
........................................................
5- 1 GENERAL 5-1
5-2 CONTAMINATION ................................................ 5-1
5.3 . CHOOSING A CLEANING PROCESS AND CLEANER ............... 5-1
........................................
5-3.1 ITEM CONSIDERATIONS 5-1
5-3.2 CLEANING PROCESS CONSIDERATIONS ........................ 5-1
5-3.3 CLEANER CONSIDERATIONS ................................... 5-2
5-4 CLEANER SELECTION CHART .................................... 5-3
...................
5-5 CLEANING PROCEDURES FOR SPECIAL ITEMS 5-3
5-6 TESTING OF CLEANLINESS ....................................... 5-5
.........................................................
5-7 DRYING 5-5
....................................................
REFERENCES 5-21
..................................................
BIBLIOGRAPHY 5-21
CHAPTER 6
PRESERVATIVES
........................................................
6- 1 GENERAL 6-1
...............................
6-2 PRESERVATION AFTER CLEANING 6-1
..............
6-3 CONSIDERATIONS IN CHOOSING A PRESERVATIVE 6-1
.......................................
6-3.1 ITEM CHARACTERISTICS 6-1
.............................
6-3.2 PRESERVATIVE CONSIDERATIONS 6-2
6-4 TYPES OF PRESERVATIVES ....................................... 6-2
................................
6-4.1 CONTACT-TYPE PRESERVATIVES 6-2
......................
6-4.2 VOLATILE CORROSION INHIBITORS (VCI) 6-13
....................................................
REFERENCES 6-13
..................................................
BIBLIOGRAPHY 6-13
CHAPTER 7
METHODS OF PRESERVATION
...............................
7- 1 PACKAGING AND PRESERVATION 7-1
....................................................
7-2 SUBMETHODS 7-1
...................
7-3 ADHERENCE AND UNIFORMITY OF METHODS 7-1
7-4 METHOD DETERMINATION ...................................... 7-1
....................................................
REFERENCE 7-7
..................................................
BIBLIOGRAPHY 7-3
iv
AMCP 706-121
TABLE OF CONTENTS (Continued)
Paragraph Page
CHAPTER 8
BARRIER MATERIALS AND CUSHIONING MATERIALS
8- 1 BARRIERS ....................................................... 8- 1
8-1.1 TYPES AND PURPOSES ......................................... 8- 1
8-1.2 SELECTION .................................................... 8- 1
8-1.3 ITEM CHARACTERISTICS ....................................... 8-15
8-1.4 BARRIER MATERIAL CHARACTERISTICS ....................... 8-15
8-1.5 STATIC CONDUCTIVITY IN PLASTIC FILMS ..................... 8-15
8-2 CUSHIONING .................................................... 8-16
8-2.1 PURPOSE ....................................................... 8-16
8-2.2 PROPERTIES ................................................... 8-16
8-2.2.1 Shock Absorption and Resilience .................................. 8-16
8-2.2.2 Texture and Workability ......................................... 8-16
8-2.2.3 Water Resistance ............................................... 8-16
8-2.2.4 Resistance to Dust .............................................. 8-16
8-2.2.5 Fungus Resistance .............................................. 8-17
8-2.3 SELECTING THE CUSHIONING MATERIAL ...................... 8-17
8-2.4 TYPES .......................................................... 8-17
8-2.4.1 Flexible Corrugated Paper ........................................ 8-18
8-2.4.2 Wool Felt ..................................................... 8-18
8-2.4.3 Glass-fiber ..................................................... 8-18
8-2.4.4 Cellulose Wadding, Cotton, and Wood-fiber Felt ..................... 8-18
8-2.4.5 Excelsior ...................................................... 8-18
8-2.4.6 Hair or Fiber and Rubber ........................................ 8-18
8-2.4.7 Foamed Sponge Rubber .......................................... 8-18
8-2.4.8 Unicellular Sponge Rubber ....................................... 8-21
8-2.4.9 Shredded Paper ................................................. 8-2 1
8-2.4.10 Mineral Wool .................................................. 8-21
8-2.4.1 1 Foamed (Cellular) Plastics ........................................ 8-2 1
REFERENCES .................................................... 8-22
CHAPTER 9
CONTAINER MATERIALS
9- 1 SELECTION OF CONTAINER MATERIALS ......................... 9- 1
9-2 TYPES OF CONTAINER MATERIALS .............................. 9- 1
9-2.1 METALS ........................................................ 9- 1
9-2.1.1 Steel .......................................................... 9-2
9-2.1.2 Aluminum ..................................................... 9-2
....................................................
9-2.1.3 Magnesium 9-3
V
AMCP 706-121
TABLE OF CONTENTS (Continued)
Paragraph Page
..............................
9-2.2 FIBERBOARD AND PAPERBOARD 9-3
............
9-2.3 WOOD. PLYWOOD. AND PAPER OVERLAID VENEER 9-5
......................................................
9-2.4 PLASTICS 9-9
........................................
9-2.5 REINFORCED PLASTICS 9-18
...................
9-3 CONTAINER MATERIALS SELECTION CHARTS 9-18
....................................................
REFERENCES 9-25
..................................................
BIBLIOGRAPHY 9-25
CHAPTER 10
EXTERIOR PROTECTION AND CONTAINERS
10-1 CONTAINER FUNCTIONS ......................................... 10-1
10-2 EXTERIOR CONTAINERS ......................................... 10-1
10-2.1 ITEM CHARACTERISTICS ....................................... 10-1
10-2.2 TYPE OF LOAD ................................................. 10-3
10-2.3 INITIAL COST OF CONTAINER ................................. 10-3
............................
10-2.4 EASE OF ASSEMBLY AND CLOSURE 10-3
10-2.5 AVAILABILITY OF MATERIALS ................................. 10-3
10-2.6 EASE IN HANDLING AND STORAGE ............................ 10-3
10-2.7 DEGREE OF PROTECTION REQUIRED .......................... 10-3
10-2.8 REUSABILITY .................................................. 10-3
10-3 STANDARD CONTAINERS ........................................ 10-9
10-3.1 BAGS AND SACKS .............................................. 10-9
19-3.2 FIBERBOARD AND PAPERBOARD CONTAINERS ................ 10-9
10-3.3 WOODEN BOXES ............................................... 10-10
10-3.4 PAILS AND DRUMS ............................................ 10-10
10-3.5 CRATES ........................................................ 10-10
10-3.6 CLOSURE TOOLS AND EQUIPMENT ............................. 10-12
10-3.7 REFERENCE .................................................... 10-13
10-4 REUSABLE METAL CONTAINERS ................................. 10-13
10-4.1 TYPES .......................................................... 10-14
10-4.2 TEMPERATURE AND PRESSURE CONSIDERATIONS ............. 10-15
10-4.3 BREATHER VALVES ............................................ 10-15
10-5 OTHER EXTERIOR PROTECTION DEVICES ........................ 10-17
10-5.1 PALLETS ....................................................... 10-21
10-5.2 CONSOLIDATION FOR SHIPMENT .............................. 10-21
10-6 TESTING OF EXTERIOR PROTECTION ............................ 10-21
REFERENCES .................................................... 10-36
BIBLIOGRAPHY .................................................. 10-36
vi
AMCP 706-1 21
TABLE OF CONTENTS (Continued)
Paragraph Page
CHAPTER 11
FASTENERS AND CLOSURES
11-1 USES AND TYPES ................................................ 11-1
11-2 FASTENERS ...................................................... 11-1
11-2.1 NAILING ....................................................... 11-2
11-2.1.1 Box Construction Defects ........................................ 11-2
11-2.1.2 Nailing Techniques .............................................. 11-2
11-2.1.3 Blocking and Bracing ............................................ 11-2
11 -2.2 CORRUGATED FASTENEKS ..................................... 11-2
11-2.3 BOLTS. SCREWS. AND RIVETS .................................. 11-3
11-2.3.1 Materials for Bolts. Screws. and Nuts .............................. 11-3
11-2.3.2 Holding Power of Bolts and Nuts .................................. 11-3
11-2.3.3 Strength of Bolted Joints ......................................... 11-3
11-2.4 SCREWS ........................................................ 11-3
11-2.5 BOLTS .......................................................... 11-3
11-2.6 STRAPPING .................................................... 11-4
11-2.6.1 Reinforcement for Blocking and Bracing ............................ 11-4
11-2.6.2 Reinforcement of Exterior Containers .............................. 11-4
11 -2.7 WOOD FASTENINGS ............................................ 11-5
11-2.8 STAPLING AND STITCHING .................................... 11-5
1 1-2.9 TWINE ......................................................... 11-5
11-3 CLOSURES ....................................................... 11-5
REFERENCES .................................................... 11-32
CHAPTER 12
TAPES AND ADHESIVES
12-1 TYPES OF TAPES ................................................. 12-1
12-1.1 PRESSURE-SENSITIVE TAPES ................................... 12-1
12-1.1.1 Cloth.backed. Pressure-sensitive Tapes .............................. 12-1
12-1.1.2 Paper.backed. Pressure-sensitive Tapes .............................. 12-1
12-1.1.3 Fi1m.backed. Pressure-sensitive Tapes .............................. 12-1
12-1.2 SOLVENT-ACTIVATED TAPES ................................... 12-1
12-2 CONSIDERATIONS IN CHOOSING A TAPE ........................ 12-4
12-3 TAPE CHARACTERISTICS ........................................ 12-5
12-4 TYPES OF ADHESIVES ............................................ 12-5
12-5 CONSIDERATIONS IN CHOOSING AN ADHESIVE .................. 12-5
12-6 ADHESIVE CHARACTERISTICS ................................... 12-5
BIBLIOGRAPHY .................................................. 12-17
vii