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Figure 3-5.  Examples of Incorrect Corner Post Inserts (Cross Section)
Figure 3-6.  Beveling Before Weld

TM-55-8115-203-23P Container General Cargo: MILVAN Container W/Mechanical Load Bracing System; MILVAN Manual
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TM 55-8115-203-23 & P (g)    Do not position an insert so that its upper or lower edge is closer than twelve inches from the corner fitting.  See figure 3.4, example E.  Instead, extend the insert all the way to the corner fitting.  An insert which butts against the corner fitting must be at ]east twelve inches long. (h)    Do not use an insert which will extend over less than three inches of the exposed corner post cross section.  See figure 3.5, example A. (i)    Do not position an insert so that its vertical edge is on the outside corner of the corner post.  See figure 3.5, example B. (j)    Do  not  use  an  insert  which  extends  across  more  than  half  of  the  corner  post  cross  section.    See figure 3.5, example C. (k) Inserts must not stick out from the corner post.  See figure 3.5, example D. (2) Remove damaged portion of corner post and prepare for inserting. (a)    Mark  around  the  damaged  area  with  chalk  or  scribe.    Mark  a  rectangular,  oval,  or  diamond  shape depending on the general shape of the damaged area.  A rectangular shape will be easiest to work with. (b)    Tack  weld  guide  bars  in  place  to  ensure  straight  cuts  with  an  oxygen  acetylene  torch.    Even, accurate cutting will eliminate wide gaps between the corner post and the new insert. (c)    Cut out the damaged area with an oxygen acetylene torch. CAUTION Direct oxygen acetylene torch away from corner castings, side and end rails, and side and end panels to prevent damage to any of these Darts. (d) Grind smooth all cut edges. (3) Cut insert. (a)    Using  guide  bars,  cut  a  replacement  insert  to  the  exact  shape  of  the  damaged  area.    The  insert material must be rolled steel with at least 110 lbs/sq.  in.  (50 kg/sq. mm) minimum tensile strength. (b)    Grind smooth cut edges of insert. (4) Fit and weld insert in place. (a)    Place insert to determine fit.  Insert should be flush against the corner post edges on all sides. (b)    Bevel edges of the insert and corner post cutout area to a thirty degree angle (See Figure 3-6). (c)    Tack weld insert in place. (d)    Continuously weld insert to corner post. 3-12







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