##### **DEPARTMENT OF TRANSPORTATION**

**PERFORMANCE ORIENTED PACKAGE TESTING**

**CERTIFICATION**

**Performed by:**

**Good Results Testing**

1 PHIMSA Ave

Nowhere, Maryland 20590

555-555-5555

**Testing Performed for:**

**Big Guy Chemical Company**

2 Old RSPA Way

Anyplace, Maryland 20590

555-555-1234

Design Qualification Testing of a

UN 4G Fiberboard Box

##### With Four 4-Liter Inner Bottles

###### 4G/X25.5/S/\*\*

> USA/+QQ2345
>
> \*\* Is to be replaced by the
>
> year of manufacture

**This package is NOT certified for shipment by air.**

**Signature of Certifying Individual**

**(Must be listed on the Laboratory's Approval)**

######## Section 2

######## Package Description 

# **Fiberboard Box: See Section 5 for drawing**

+------------------------------+---------------------------------------+
| Manufacturer:                | Big Box Company,                      |
|                              |                                       |
|                              | Springfield, MD                       |
+------------------------------+---------------------------------------+
| Box Style:                   | Regular Slotted Container (RSC)       |
|                              |                                       |
|                              | International Box Code: 0201          |
|                              |                                       |
|                              | Mullen Burst [\_\_X\_]{.underline}    |
|                              | ECT \_\_\_\_                          |
+------------------------------+---------------------------------------+
| Part Number:                 | BB12345                               |
+------------------------------+---------------------------------------+
| Boxmaker's Certification:    | None                                  |
+------------------------------+---------------------------------------+
| Outer dimensions cm (in):    | 30.8 x 30.5 x 30.0 (12.0 x 12.0 x     |
|                              | 12.0)                                 |
+------------------------------+---------------------------------------+
| Inner Dimensions cm (in      | 29.6 x 29.3 x 29.0 (11.5 x 11.5 x     |
|                              | 11.5)                                 |
+------------------------------+---------------------------------------+
| Manufacturers Joint:         | Hot Melt Glued with a 4.4 cm (1.75)   |
|                              | inside flap                           |
+------------------------------+---------------------------------------+
| Tare Weight                  | 525 grams                             |
+------------------------------+---------------------------------------+

  ------------------------------ ----------------------------------------
  Partitions (if used)           

  Partition Style                

  Dimensions                     

  Tare Weight                    
  ------------------------------ ----------------------------------------

**Basis Weights of Box and Partitions:**

+----------+------------------------+-----------------+---------------+
| # Item   | Facing or Corrugation  | Location        | Basis Weight  |
+----------+------------------------+-----------------+---------------+
| Box      | Facing                 | Inner           | 42.1          |
+----------+------------------------+-----------------+---------------+
|          | Facing                 | Middle          | 26.2          |
+----------+------------------------+-----------------+---------------+
|          | Facing                 | Outer           | 36.5          |
+----------+------------------------+-----------------+---------------+
|          | Corrugation            | Inner- B Flute  | 26.1          |
+----------+------------------------+-----------------+---------------+
|          | Corrugation            | Outer -- B      | 26.2          |
|          |                        | Flute           |               |
+----------+------------------------+-----------------+---------------+
| P        | Facings                |                 |               |
| artition |                        |                 |               |
+----------+------------------------+-----------------+---------------+
|          | Facing                 |                 |               |
+----------+------------------------+-----------------+---------------+
|          | Corrugation            |                 |               |
+----------+------------------------+-----------------+---------------+

######## 

######## Combined Board Caliper 

  ----------------- ----------------- ----------------- -----------------
  Box               5.9 mm            6.3 mm            6.3 mm

  Partition                                             
  ----------------- ----------------- ----------------- -----------------

# Combined Facing Weights (average)

  ----------------------------------- -----------------------------------
  Box                                 

  Partition                           
  ----------------------------------- -----------------------------------

#  

# 

# **Inner Bottles: See Section 5 for drawing**

+-------------------+----------------------+--------------------------+
| Manufacturer:     | Joe's Bottle Company |                          |
|                   |                      |                          |
|                   | Houston, TX          |                          |
+-------------------+----------------------+--------------------------+
| Part Number:      | JB11111-11           |                          |
+-------------------+----------------------+--------------------------+
| Manufacturing     | Blow molded          |                          |
| Method            |                      |                          |
+-------------------+----------------------+--------------------------+
| Material/Resin:   | HDPE                 | Some Chemical Company    |
|                   |                      |                          |
|                   |                      | Resin 12345              |
+-------------------+----------------------+--------------------------+
| Capacity          | Nominal              | 4.00 liters              |
+-------------------+----------------------+--------------------------+
|                   | Maximum\* (avg.)     | 4.15 liters              |
+-------------------+----------------------+--------------------------+
| Dimensions:       | Width                | 146.6 mm (5.776 in)      |
+-------------------+----------------------+--------------------------+
|                   | Length               | 147.7 mm (5.819 in)      |
+-------------------+----------------------+--------------------------+
|                   | Height:              | 272.8 mm (10.740 in)     |
+-------------------+----------------------+--------------------------+
| Min Thickness:    | Bottom:              | 2.0 mm (0.078 in)        |
+-------------------+----------------------+--------------------------+
|                   | Sides:               | 1.0 mm (0.039 in)        |
+-------------------+----------------------+--------------------------+
| Average           | Bottom:              | 2.3 mm                   |
| Thickness:        |                      |                          |
+-------------------+----------------------+--------------------------+
|                   | Sides:               | 1.2 mm                   |
+-------------------+----------------------+--------------------------+
| Tare Weight       |                      | 145.0 grams              |
| (avg.)            |                      |                          |
+-------------------+----------------------+--------------------------+

# 

# 

# 

# 

# **Closure: See Section 5 for drawing**

+--------------------+----------------------+--------------------------+
| Manufacturer:      | Sam's Closures       |                          |
|                    |                      |                          |
|                    | Houston, TX          |                          |
+--------------------+----------------------+--------------------------+
| Part Number:       | SC-38                |                          |
+--------------------+----------------------+--------------------------+
| Material:          | Polypropylene        |                          |
+--------------------+----------------------+--------------------------+
| Closure Weight:    | 5.5 grams            |                          |
+--------------------+----------------------+--------------------------+
|                    |                      |                          |
+--------------------+----------------------+--------------------------+
| Dimensions:        | Diameter             | 40.0.0 mm                |
+--------------------+----------------------+--------------------------+
|                    | Height               | 11.46 mm                 |
+--------------------+----------------------+--------------------------+
|                    | Thickness (min):     | 2.0 mm                   |
+--------------------+----------------------+--------------------------+
| ########           | Material             | Foam                     |
| Lining -- Glued in |                      |                          |
+--------------------+----------------------+--------------------------+
| #                  | Diameter             | 38.0mm                   |
+--------------------+----------------------+--------------------------+
|                    | Thickness            | 1.2 mm                   |
+--------------------+----------------------+--------------------------+

**Closing Methods:**

+-----------------------------------+-----------------------------------+
| Sealing Method for the fiberboard | # 3 strip                         |
| box                               | s of 2 inch fiber reinforced tape |
|                                   |  applied in an "H" pattern on the |
|                                   |  top and bottom of the box. Sides |
|                                   |  are taped approximately ½ inch f |
|                                   | rom the corners of the box. The c |
|                                   | enter tape extends approximately  |
|                                   | 2 inches over the end of the box. |
+-----------------------------------+-----------------------------------+
| Closing torque of caps for all    | # 12.0 in-lbs +/- 2.5 in-lbs      |
| testing:                          |                                   |
+-----------------------------------+-----------------------------------+

# 

# **Additional Test Information** 

  -------------------------------------- --------------------------------
  Overall Tare Weight of Package         1.13 kg

  Test Contents:                         Water and antifreeze

  Specific gravity                       .98

  Minimum Weight of Package as Tested:   17.41 kg

  Authorized Package Gross Weight based  25.5
  on SG 1.5                              
  -------------------------------------- --------------------------------

**Section 3 - TESTING**

**Test Descriptions and Results**

######## Package Preparation -- For All Testing

The packages were filled to a minimum of 98% full (see Section 4 for
calculation). The inner bottles were inserted as shown in Section 5.

######## Drop Test -- 

Test Method: 49 CFR 178.603

Number of Packages Tested -- 5

Drop Height -- 2.25 meters (Calculation for the drop height is provided
in Section 4)

Testing was conducted to certify the package for PGI liquids with a
specific gravity of up to 1.5.

Conditioning

The packages were conditioned to --18 degrees C in accordance with 49
CFR 178.603(c). The packages were conditioned for 24 hours to ensure the
package and contents were at the proper temperature prior to testing.
Drop testing was conducted approximately 2 minutes after removing the
test package from the conditioning chamber.

# **Results**

+-------+-------------+-------------------+----------------------------+
| Box   | Package     | Orientation       | Result                     |
|       |             |                   |                            |
| N     | Weight      |                   |                            |
| umber |             |                   |                            |
+-------+-------------+-------------------+----------------------------+
| # 1   | # 17.42     | # Flat on Top     | Pass -- No damage          |
+-------+-------------+-------------------+----------------------------+
| 2     | 17.43       | Flat on Short     | Pass -- No damage          |
|       |             | Side              |                            |
+-------+-------------+-------------------+----------------------------+
| 3     | 17.41       | Flat on Bottom    | Pass -- No damage          |
+-------+-------------+-------------------+----------------------------+
| 4     | 17.45       | Flat on Long Side | Pass -- No damage          |
+-------+-------------+-------------------+----------------------------+
| 5     | 17.44       | Bottom Corner     | Pass -- Corner crushed     |
|       |             |                   | approximately 2 inches, no |
|       |             |                   | release of the inner       |
|       |             |                   | packages from the outer    |
|       |             |                   | package or filling         |
|       |             |                   | substance from the inner   |
|       |             |                   | bottle.                    |
+-------+-------------+-------------------+----------------------------+

######## Pass/Fail Criteria - 

A package is considered to successfully pass the drop tests if for each
sample tested: There is no damage to the outer packaging likely to
adversely affect safety during transport, there is no leakage of the
filling substance from the inner packaging and any discharge from a
closure is slight and ceases immediately after impact.

######## 

######## Stacking Test 

Test Method: 49 CFR 178.606

Free standing: [X]{.underline}

Guided Load: \_\_

Packages Tested -- 3

Test Duration: 24 hours

The packages were conditioned in accordance with 49 CFR 178.602(d) to
50% RH +/- 2% at 23 C for 24 hours.

Stacking Test Weight -- 250 kg (rounded up from 229.95)

See Section 4 for Calculation

The stacking test load was applied to the top of the packages by loading
each package with 830 kg and the weight was maintained for 24 hours.

Results:

  --------------------- -------------------------------------------------
  Package 1             No damage to the packaging

  Package 2             No damage to the packaging

  Package 3             No damage to the packaging
  --------------------- -------------------------------------------------

Note: Stacking stability was not assessed since a guided load test was
not performed.

Pass/Fail Criteria -

No test sample may leak. There must be no leakage of the filling
substance from the inner receptacle, or inner packaging. No test sample
may show any deterioration which could adversely affect transportation
safety or any distortion likely to reduce its strength, cause
instability in stacks of packages, or cause damage to inner packagings
likely to reduce safety in transportation.

#  

# **Vibration Standard**

Packages Tested -- 3

Test Method: 49 CFR 178.608 on a: \_\_ rotary vibration table

\_\_ vertical linear vibration table

Duration: 1 Hour

Frequency: 3.6 Hz (216 rpm)

Results

  ----------------------------------- -----------------------------------
  Package 1                           No damage

  Package 2                           No damage

  Package 3                           No damage
  ----------------------------------- -----------------------------------

Pass/Fail Criteria -

A packaging passes the vibration test if there is no rupture or leakage
from any of the packages. No test sample should show any deterioration
which could adversely affect transportation safety or any distortion
liable to reduce packaging strength.

######## 

######## 

######## 

######## 

######## 

######## 

######## Cobb Test

# Test Method: ISO International Standard 535 as required by 49 CFR 178.516(b)(1).

Samples were taken from the boxes and subjected to a water absorption
test in accordance with ISO International Standard 535.

Samples tested - 5

Results

  ------------------------- -------------------------- ------------------
  Sample Number             Water Absorption           Pass/Fail

  Sample 1                  97 g/m3                    

  Sample 2                  94 g/m3                    

  Sample 3                  96 g/m3                    

  Sample 4                  92 g/m3                    

  Sample 5                  91 g/m3                    

  Average                   94.0                       Pass
  ------------------------- -------------------------- ------------------

**Pass/Fail Criteria:**

An increase in mass of greater than 155 g/m2 over the 30 minute duration
of the test represents an unacceptable level of water resistance.

**Section 4 - Calculations**

1.  **Weight of test package**

Weight of Box 0.525 kg

Weight of Bottle + Cap 0.151 kg

Capacity of bottle 4.15 liter

**Empty Package weight**

Box + Partitions .525 kg

Empty Bottles (4 x.151) .604 kg

Total 1.129 kg

**Filled Package Weight**

Weight of liquid fill .98 X 4.15= 4.07 kg

# Weight of Filled Package 

# 0.525 + 4(.151) + 4(4.07) = 17.41 kg

2.  **Drop Test Height**

# Specific Gravity of Certification 1.5

Packaging Group of Certification I

For PG I SG x 1.5 meters

1.5 x 1.5 meters = 2.25 meters

3.  **Marked Weight to Accommodate SG 1.5**

Weight of Fill 4(4.07 kg) x 1.5 = 24.42 kg

Weight of Box 0.525 kg

Weight of Bottles 0.604 kg

# Marked Weight (rounded down) 25.5 kg

4.  **Stack Test Weight**

Load = (n-1)\[W+Q(L x S)\]

Where:

N = number of containers to reach 3 meters

W= Tare weight of all packaging material

Q= Quantity of Inner Packages

L = Weight of Liquid Fill

S = Maximum Specific Gravity

Package Height = 30.0 cm

3.0 meters/.30 meters = 10.0

(10-1)\[1.13+4(4.07 x 1.50)\] = 229.95 kg

**Section 5**

**Drawings of Packaging Components**

######## Fiberboard Box

![](media/image1.wmf){width="3.5in" height="2.875in"}

![](media/image1.wmf){width="4.125in" height="4.25in"}

**Closure**

![](media/image2.wmf){width="3.597916666666667in"
height="1.1166666666666667in"}

######## 

######## 

######## 

######## 

######## 

######## 

######## 

######## 

######## Inner Bottle

![](media/image3.wmf){width="4.802777777777778in"
height="4.391666666666667in"}

**Appendix A**

######## Test Equipment and Instrumentation

  -------------- -------------- -------------- -------------- --------------
  Instrument or  Manufacturer   Model Number   Serial Number  Calibration
  Equipment                                                   Date

  Drop Tester                                                 

  Gram Scale                                                  

  Electronic                                                  
  Scale                                                       

  Pressure Gauge                                              

  Vibration                                                   
  Table                                                       

                                                              
  -------------- -------------- -------------- -------------- --------------

**Appendix B**

**Additional boxes indicated below are certified through selective
testing provisions:**

  ----------------------- ----------------------- -----------------------
  Part Number             Dimensions              

  23456                   11.00 x 11.00 x 11.00   

  34567                   12.00 x 11.00 x 9.00    

  45678                   9.00 x 9.00 x 9.00      

  56789                   6.00 x 6.00 x 6.00      
  ----------------------- ----------------------- -----------------------