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Designation: D 4169 – 08
Standard Practice for
Performance Testing of Shipping Containers and Systems
1
This standard is issued under the fifixed designation D 4169; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the Department of Defense.
1. Scope
1.1 This practice provides a uniform basis of evaluating, in
a laboratory, the ability of shipping units to withstand the
distribution environment. This is accomplished by subjecting
them to a test plan consisting of a sequence of anticipated
hazard elements encountered in various distribution cycles.
This practice is not intended to supplant material specififications
or existing preshipment test procedures.
1.2 This practice does not include performance testing of
packages for single parcel shipments (see Practice D 7386).
1.3 The suitability of this practice for use with hazardous
materials has not been determined.
1.4 The values stated in inch-pound units are to be regarded
as standard. The values given in parentheses are mathematical
conversions to SI units that are provided for information only
and are not considered standard.
1.5 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appro
priate safety and health practices and determine the applica
bility of regulatory limitations prior to use.
2. Referenced Documents
2.1 ASTM Standards:
2
D 642 Test Method for Determining Compressive Resis
tance of Shipping Containers, Components, and Unit
Loads
D 880 Test Method for Impact Testing for Shipping Con
tainers and Systems
D 951 Test Method for Water Resistance of Shipping Con
tainers by Spray Method
D 996 Terminology of Packaging and Distribution Environ
ments
D 999 Test Methods for Vibration Testing of Shipping
Containers
D 4003 Test Methods for Programmable Horizontal Impact
Test for Shipping Containers and Systems
D 4332 Practice for Conditioning Containers, Packages, or
Packaging Components for Testing
D 4728 Test Method for Random Vibration Testing of
Shipping Containers
D 5265 Test Method for Bridge Impact Testing
D 5276 Test Method for Drop Test of Loaded Containers by
Free Fall
D 5277 Test Method for Performing Programmed Horizon
tal Impacts Using an Inclined Impact Tester
D 5487 Test Method for Simulated Drop of Loaded Con
tainers by Shock Machines
D 6055 Test Methods for Mechanical Handling of Unitized
Loads and Large Shipping Cases and Crates
D 6179 Test Methods for Rough Handling of Unitized
Loads and Large Shipping Cases and Crates
D 6344 Test Method for Concentrated Impacts to Transport
Packages
D 6653 Test Methods for Determining the Effects of High
Altitude on Packaging Systems by Vacuum Method
D 7386 Practice for Performance Testing of Packages for
Single Parcel Delivery Systems
F 1327 Terminology Relating to Barrier Materials for Medi
cal Packaging
3
2.2 Military Standards:
4
MIL-STD-810F Environmental Test Methods
MIL-STD-2073–1 DOD Standard Practice for Military
Packaging
3. Terminology
3.1 Defifinitions—General defifinitions for the packaging and
distribution environments are found in Terminology D 996.
1
This practice is under the jurisdiction of ASTM Committee D10 on Packaging
and is the direct responsibility of Subcommittee D10.21 on Shipping Containers and
Systems - Application of Performance Test Methods.
Current edition approved Aug. 1, 2008. Published August 2008. Originally
approved in 2004. Last previous edition approved in 2005 as D 4169 – 05.
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website.
3
Withdrawn.
4
Available from Standardization Documents Order Desk, Bldg. 4 Section D, 700
Robbins Ave., Philadelphia, PA 19111-5094, Attn: NPODS.
1
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3.2 Defifinitions of Terms Specifific to This Standard:
3.2.1 acceptance criteria—the acceptable quality level that
must be met after the shipping unit has been subjected to the
test plan. See Section 7.
3.2.2 assurance level—the level of test intensity based on
its probability of occurring in a typical distribution cycle.
3.2.2.1 Discussion—Level I is a high level of test intensity
and has a low probability of occurrence. Level III is a low level
of test intensity, but has a correspondingly high probability of
occurrence. Level II is between these extremes. For Distribu
tion Cycle 18 (DC–18), see MIL-STD-2073–1 for defifinitions
of military levels of protection.
3.2.3 coeffıcient of restitution—the ratio of the rebound
velocity to the impact velocity.
3.2.4 distribution cycle (DC)—the sequential listing of the
test schedules employed to simulate the hazard elements
expected to occur for a specifific routing of a shipping unit from
production to consumption. See Table 1.
3.2.5 feeder aircraft—small, potentially non-pressurized
aircraft used to transport express packages.
3.2.6 hazard element—a specifific event that occurs in a
distribution cycle that may pose a hazard to a shipping unit.
The element will usually be simulated by a single test schedule.
See Section 9.
3.2.7 shipping unit—the smallest complete unit that will be
subjected to the distribution environment, for example, a
shipping container and its contents.
3.2.7.1 small shipping unit—for DC-18, a small shipping
unit is defifined as one having no edge dimension or diameter
over 60 in. (1.52 m) and a gross weight of 100 lb (45 kg) or
less.
3.2.7.2 large shipping unit—for DC-18, a large shipping
unit is defifined as one having at least one edge dimension or
diameter over 60 in. (1.52 m) or a gross weight in excess of 100
lb (45 kg), or it is one that has a gross weight exceeding 100 lb
(45 kg) and is secured to a base or to the base of a shipping
unit.
3.2.8 test plan—a specifific listing of the test sequence to be
followed to simulate the hazards anticipated during the distri
bution cycle of a shipping unit. Included will be the test
intensity and number of sequential tests to be conducted. See
8.5.
3.2.9 test schedule—the specifific procedure to be used,
including the three assurance level intensities, and a reference
to the test method that is the basis of the schedule.
3.2.9.1 Discussion—The purpose of the schedule is to
simulate the forces occurring during any hazard element of the
distribution cycle. See Section 9.
3.2.10 total velocity change, (DV)—the sum of the impact
and rebound velocities.
3.3 Abbreviations:
3.3.1 TOFC—trailer on flflatcar.
3.3.2 COFC—container on flflatcar.
3.3.3 TL—truckload.
3.3.4 CL—carload.
3.3.5 LTL—less than truckload.
4. Signifificance and Use
4.1 This practice provides a guide for the evaluation of
shipping units in accordance with a uniform system, using
established test methods at levels representative of those
occurring in actual distribution. The recommended test levels
are based on available information on the shipping and
handling environment, and current industry/government prac
tice and experience (1-13).
5
The tests should be performed
sequentially on the same containers in the order given. For use
as a performance test, this practice requires that the shipping
unit tested remain unopened until the sequence of tests are
completed. If used for other purposes, such as package
development, it may be useful to open and inspect shipping
units at various times throughout the sequence. This may,
however, prohibit evaluating the inflfluence of the container
closure on container performance.
4.2 For Distribution Cycle 18, as referred to in MIL-STD-
2073–1, the use of this practice is defifined in subsequent
sections identifified as DC-18.
5. Test Specimen
5.1 Test specimens consist of representative samples of
complete shipping units, including actual contents. Products
with blemishes or minor defects may be used if the defective
component is not to be studied by the test and if the defect is
documented in the report. Dummy test loads are acceptable if
testing the actual product might be hazardous. If a dummy load
is used, it should be instrumented to determine if the fragility
level of the actual product has been exceeded. Take care to
duplicate the load characteristics of the actual product, and
avoid unnecessary prehandling.
5.2 Care must be taken to ensure that no degradation has
occurred to either the product or the package if the test
packages have been shipped to the test site. If any doubt exists
as to the condition of the package, repack the product in new
packaging material before testing.
5.3 The number of test replications depends on the desired
objectives of the testing and the availability of duplicate
products and shipping containers. Replicate testing is recom
mended to improve the reliability of the test results.
6. Conditioning
6.1 If the distribution cycle contains climatic conditions that
have an effect on the performance characteristics of the
product, shipping container, or components such as cushioning,
use one of the following procedures. (It should be noted that
different atmospheric conditions are likely to exist between the
origin and destination points of a distribution cycle, particu
larly for export/import cycles.)
6.1.1 Conduct the test at standard conditions and compen
sate for the effects of any climatic condition. Condition the
shipping units to a standard atmosphere of 73.4 6 2°F (23 6
1°C) and 50 6 2 % relative humidity. Condition fifiberboard
containers in accordance with Practice D 4332. The same
atmospheric condition should be used for any assurance level.
5
The boldface numbers in parentheses refer to a list of references at the end of
this practice.
D 4169 – 08
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TABLE 1 Distribution Cycles
Performance Test Schedule Sequence
(see Section 9 for Test Schedule defifinition)
DC Distribution Cycle First Second Third Fourth Fifth Sixth Seventh
1 General Cycle—undefifined distribution
system
Schedule
A
Handling
Schedule D Stacked
Vibration
Schedule F
Loose-Load
Vibration
Schedule G
Rail
Switching
Schedule J
Concentrated
Impact
Schedule A
Handling
2 Specially defifined distribution system,
user specifified (see Appendix X2)
select from Schedules A through I
3 Single package without pallet or skid,
LTL motor freight
Schedule
A
Handling
—Manual
Schedule D Stacked
Vibration OR
Schedule C Vehicle
Stacking plus
Schedule E Vehicle
Vibration
Schedule F
Loose-Load
Vibration
Schedule J
Concentrated
Impact
Schedule A
Handling—
Manual
...
4 Single package with pallet or skid,
LTL motor freight
Schedule
A
Handling
—Mechanical
Schedule D Stacked
Vibration OR
Schedule C Vehicle
Stacking plus
Schedule E Vehicle
Vibration
Schedule F
Loose-Load
Vibration
Schedule J
Concentrated
Impact
Schedule A
Handling—
Mechanical
...
5 Motor freight, TL, not unitized Schedule
A
Handling
Schedule D Stacked
Vibration
Schedule E
Vehicle
Vibration
Schedule J
Concentrated
Impact
Schedule A
Handling
...
6 Motor freight, TL, or LTL—unitized Schedule
A
Handling
Schedule D Stacked
Vibration OR
Schedule C Vehicle
Stacking plus
Schedule E Vehicle
Vibration
Schedule J
Concentrated
Impact
Schedule A
Handling
Schedule B
Warehouse
Stacking
...
7 Rail only, bulk loaded Schedule
A
Handling
Schedule D Stacked
Vibration
Schedule G
Rail
Switching
Schedule A
Handling
... ...
8 Rail only, unitized Schedule
A
Handling
Schedule D Stacked
Vibration
Schedule G
Rail
Switching
Schedule A
Handling
Schedule B
Warehouse
Stacking
...
9 Rail and motor freight, not unitized Schedule
A
Handling
Schedule C Vehicle
Stacking
Schedule E
Vehicle
Vibration
Schedule G
Rail
Switching
Schedule F
Loose-Load
Vibration
Schedule J
Concentrated
Impact
Schedule A
Handling
10 Rail and motor freight, unitized Schedule
A
Handling
Schedule D Stacked
Vibration
Schedule G
Rail
Switching
Schedule J
Concentrated
Impact
Schedule A
Handling
Schedule B
Warehouse
Stacking
11 Rail, TOFC and COFC Schedule
A
Handling
Schedule G Rail
Switching
Schedule D
Stacked
Vibration
Schedule F
Loose-Load
Vibration
Schedule A
Handling
...
12 Air (intercity) and motor freight (local),
over 100 lb (45.4 kg), unitized
Schedule
A
Handling
Schedule D Stacked
Vibration
Schedule I
Low
Pressure
A
Schedule E
Vehicle
Vibration
Schedule J
Concentrated
Impact
Schedule A
Handling
13 Air (intercity) and motor freight (local,
single package up to 100 lb (45.4 kg)
Schedule
A
Handling
Schedule C Vehicle
Stacking
Schedule F
Loose-Load
Vibration
Schedule I
Low
Pressure
A
Schedule E
Vehicle
Vibration
Schedule J
Concentrated
Impact
Schedule A
Handling
14 Warehousing (partial cycle to be added to
other cycles as needed)
Schedule
A
Handling
Schedule B
Warehouse Stacking
... ... ... ...
15 Export/Import shipment for intermodal
container or roll on/roll off trailer (partial
cycle to be added to other cycles as
needed)
Schedule
A
Handling
Schedule C Vehicle
Stacking
Schedule A
Handling
... ... ...
16 Export/Import shipment for palletized cargo
ship (partial cycle to be added to
other cycles as needed)
Schedule
A
Handling
Schedule C Vehicle
Stacking
Schedule A
Handling