ASTM D5118.pdf

Designation: D 5118/D 5118M – 05ae1

Standard Practice for Fabrication of Fiberboard Shipping Boxes1

This standard is issued under the fixed designation D 5118/D 5118M; 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 (e) indicates an editorial change since the last revision or reapproval.

This standard has been approved for use by agencies of the Department of Defense.

e1 NOTE—Section references in subsection 6.2.1.11(2) and 6.4.2.1(1) were editorially corrected in January 2007.

1. Scope

1.1 This practice covers the fabrication of new fiberboard

boxes, liners and sleeves.

1.2 This practice points out the factors and components that

must be controlled in the manufacture of corrugated and solid fiberboard boxes, liners and sleeves.

1.3 This practice does not cover the adequacy of fiberboard

containers under all conditions of exposure to atmosphere, handling, shipping and storage.

1.4 The values stated in either inch-pound units or SI units

are to be regarded separately as standard. Within the text, the SI units are shown in brackets. The values stated in each system are not exact equivalents; therefore, each system must be used independently of the other. Combining values from the two systems may result in non-conformance with the 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 685 Practice for Conditioning Paper and Paper Products for Testing

D 996 Terminology of Packaging and Distribution Environ-ments

D 1974 Practice for Methods of Closing, Sealing, and Reinforcing Fiberboard Boxes

D 2658 Test Method for Determining Interior Dimensions of Fiberboard Boxes (Box Gage Method)

D 3950 Specification for Strapping, Nonmetallic (and Join-ing Methods)

D 3951 Practice for Commercial Packaging D 3953 Specification for Strapping, Flat Steel and Seals D 4727/D 4727M Specification for Corrugated and Solid

Fiberboard Sheet Stock (Container Grade) and Cut Shapes

2.2 Federal Specifications:3

CID A-A-59692 Adhesives, Water-Resistant (For Closure of Fiberboard Boxes)

FED-STD-123 Marking for Shipment (Civil Agencies) MIL-STD-129 Military Marking for Shipment and Storage

2.3 Code of Federal Regulations:3

Title 49

2.4 Other Publications:

National Motor Freight Classification4

Uniform Freight Classification5

Federal Food, Drug and Cosmetic Act6

3. Terminology

3.1 Definitions of terms relating to packaging are found in

Terminology D 996.

4. Significance and Use

4.1 Corrugated and solid fiberboard boxes, sleeves and

liners are used to unitize products into packages of size and shape suitable for manual or mechanical handling and to protect the contents against environmental, handling, shipping, and storage conditions.

1 This practice is under the jurisdiction of ASTM Committee D10 on Packaging and is the direct responsibility of Subcommittee D10.27 on Paper and Paperboard Products.

Current edition approved Oct. 1, 2005. Published November 2005. Originally approved in 1990. Last previous edition approved in 2005 as D 5118/D 5118M – 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 Available from Standardization Documents, Order Desk, Bldg. 4, Section D, 700 Robbins Ave., Philadelphia, PA 19111-5094, attn: NPODS.

4 Available from National Motor Freight Classification, Inc., 2200 Mill Road, Alexandria, VA 22314.

5 Available from National Railroad Freight Committee, 151 Ellis Street, N.E., Suite 260, Atlanta, GA 30335–6021.

6 Available from the Superintendent of Documents, US Government Printing Office, Washington, DC 20402.

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4.2 This practice covers some of the basic constructions and

styles of commercially available fiberboard packaging used to unitize and protect contents.

4.3 Use of Other Specifications—Nothing in this practice

shall be construed to prohibit the use of boxes of special design or of fiberboard packages identified by package number in the current Uniform Freight Classification and National Motor Freight Classification when in the experience and judgement of the purchaser, the nature of the articles or material to be shipped justifies such boxes or packages. Some commodities may require less protection while other commodities may require better boxes than are specified herein. Containers for explosives and dangerous articles must also comply with regulations for the Transport of Hazardous Materials (CFR Title 49).

5. Styles

5.1 Fiberboard boxes covered by this practice may be of the

following styles:

5.1.1 RSC/02017—Regular slotted box (Fig. 8).

5.1.2 OSC/02027—Overlap slotted box (Fig. 9).

5.1.3 FOL/02037—Full overlap slotted box (Fig. 10).

5.1.4 SFF/02067—Special full flap slotted box (Fig. 11).

5.1.5 CSSC/02047—Center special slotted box (Fig. 12).

5.1.6 CSOSC/02057—Center special overlap slotted box

(Fig. 12).

5.1.7 HSCC/03127—Half slotted box with cover (Fig. 13).

5.1.8 DBLCC/03107—Double cover box (Fig. 14).

5.1.9 IC/03257—Interlocking double cover box (Fig. 15).

5.1.10 FTC/03017—Full telescope box (Fig. 16).

5.1.11 FTHS/03207—Full telescope half slotted box (Fig.

18).

7 Available from European Federation of Manufacturers of Corrugated Board (FEFCO), 37 Rue d’Amsterdam, 75008, Paris, France. Also known as the International Box Code System, that is, in RSC/0201, RSC stands for regular slotted container and 0201 is the international box code number for the RSC.

FIG. 1 Fiberboard Box Dimensioning

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5.1.12 OPF/04017—One piece folder (Fig. 19).

5.1.13 FPF/04107—Five panel folder (Fig. 20).

5.1.14 TS—Rigid Box/0600 Series–Bliss Style Box (Fig.

17).

FIG. 2 Box, Fiberboard; Detail of Manufacturer’s Joint Construction for Class Weather Resistant and WWVR Boxes

FIG. 3 Box, Fiberboard; Details of Manufacturer’s Joint Types

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5.1.15 TSC—Tongue and slot closure box (Fig. 21).

5.1.16 TS—Triple Slide Box (Fig. 22).

5.2 Other styles may also be applicable (see 8.1.3).

6. Requirements

6.1 Materials:

6.1.1 Fiberboard shall conform to type, class, variety, and

grade of Specification D 4727 unless otherwise specified. Flute structure shall be as specified in Specification D 4727 (see 8.1.2).

6.1.2 Manufacturer’s joints shall be secured by one of the

following materials: (The joint is that seam of a box where the ends of the box blank are joined.)

NOTE 1—Dimension and cube can be boxmaker’s certificate, round or rectangular as applicable and may be located on the box where it is customarily placed.

NOTE 2—Dimensions and cube other than specified in MIL-STD-129 shall be printed only on government procured boxes.

FIG. 4 Compliance Marking for Class Weather-Resistant and WWVR Boxes

FIG. 5 Cover Assembly

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6.1.2.1 Cold adhesive shall conform to CID-A-A-59692

and as specified herein. When boxes are used for packaging or packing food and the adhesive used may contact or be in proximity to the food, the adhesive shall comply with the Federal Food, Drug and Cosmetic Act and regulations promul-gated thereunder.

6.1.2.2 Hot melt adhesives can be used when gross weight

does not exceed 65 lb [30 kg], by overlapping the sides of box forming the joint not less than 1 1⁄4 in. [32 mm] and by firmly gluing this joint with hot melt adhesive consisting of 100 % solids contents of thermal-plastic materials, which will main-tain bond at temperatures ranging from –20°F [–29°C] to +165°F [+74°C] above zero.

6.1.2.3 Metal fasteners shall be commercially preformed

staples or staples formed from commercial steel stitching wire.

All metal fasteners shall have commercially applied coating of zinc or copper wash.

FIG. 6 Box, Fiberboard; SL—Sleeve

FIG. 7 Box, Fiberboard; L—Liner

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6.1.2.4 Manufacturer’s joint tapes shall be of the following

constructions:

(1) For boxes not exceeding 65 lb [30 kg] gross weight sealing strips must not be less than 2 in. [51 mm] wide, and must comply with one of the following requirements:

(a) Two thicknesses of sulphate paper, total basis weight not less than 80 lb [130 g/m2] combined with a water-resistant compound and reinforced with not less than double strand nylon fiber not less than 210 denier forming a pattern with strands not more than 1⁄2 in. [13 mm] apart.

(b) Cloth having crosswise (filler) threads having a minimum tearing strength of 40 Elemendorf units. Inside and outside strips of sulphate paper not less than 2 in. [51 mm] wide; outside strip having a basis weight of not less than 60 lb [100 g/m2] having a bursting strength of not less than 60 psi [414 kPa]; inside strip having a basis weight not less than 40 lb [65 g/m2], and a bursting strength of not less than 40 psi [275 kPa].

(2) For boxes exceeding 65 lb [30 kg] gross weight, sealing strips must be not less than 3 in. [76 mm] wide, unless otherwise provided, and must comply with one of the follow-ing requirements:

(a) One thickness of sulphate paper, the fibers of which are integrally bonded and reinforced with rubber, basis weight not less than 175 lb [285 g/m2], embossed and varnished. Two thicknesses of sulphate paper, total basis weight not less than 80 lb [130 g/m2], reinforced in the cross direction with alternating bands of 840 denier and 420 denier nylon, not less than 4 bands every 2 in. [51 mm]. One thickness of sulphate paper having a basis weight not less than 70 lb [114 g/m 2] reinforced in the cross direction with alternating bands of 840 denier and 420 denier nylon, not less than 4 bands every 2 in.

[51 mm], nylon bands firmly adhered to the surface of the paper by means of a water-resistant compound.

NOTE 1—Kraft tape basis weights are calculated as a ream weight of 500 sheets of 24 in. [610 mm] by 36 in. [915 mm] paper. The base stocks are 90 lb [41 kg], 120 lb [55 kg] or 140 lb [64 kg] kraft ream weight. These convert to 30 lb/1000 ft2 [150 g/m2], 40 lb/1000 ft 2[195 g/m2], and 47 lb/1000 ft2 [230 g/m2] kraft liner board equivalents.

(b) Two thicknesses of sulphate paper, total basis weight not less than 80 lb [130 g/m2] combined with a water-resistant compound and with reinforcing as follows:

—With glass, rayon, or glass and rayon fibers combined, running crosswise of tape not more than 3⁄8 in. [10 mm] apart, the rayon fibers to be not less than 1100 denier.

—With glass fibers in a diamond pattern the sides of which, parallel to each other, are formed by a cluster of yarn not less than two per inch as measured in the machine direction. Each cluster shall be formed of at least two 150-1/0 threads or the equivalent in weight of 75-1/0 yarn.

FIG. 8 Box, Fiberboard; RSC—Regular Slotted Box (0201)

FIG. 9 Box, Fiberboard; OSC—Overlap Slotted Box (0202)

FIG. 10 Box, Fiberboard; FOL—Full Overlap Slotted Box (0203)

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(c) Two thicknesses of sulphate paper, one 30 lb [50 g/m2] basis weight and the other 60 lb [98 g/m 2] basis weight reinforced with cotton or linen fibers.

(d) Two or more thicknesses of sulphate paper, total basis weight not less than 150 lb [244 g/m2] and having a bursting strength of not less than 150 psi [1034 kPa], all plies firmly glued together not less than 1⁄4 in. [6 mm] wide along both edges. Cloth having crosswise (filled) threads having a mini-mum tearing strength of 70 Elemendorf units. Inside and outside strips of sulphate paper not less than 2 in. [50.0 mm] wide, each having a basis weight not less than 90 lb [147 g/m2], and having a bursting strength of not less than 90 psi [621 kPa].

6.2 Boxes shall be designed for type, class, variety, and

grade as set forth in Specification D 4727, Tables 1 and 2, and styles specified herein (see 5.1, 5.2 and 6.2.1).

6.2.1 Style:

6.2.1.1 The style of box or folder shall be as specified (see

8.1.3). The location of the openings shall be determined by the specified dimensions, which shall always be furnished in the order of length, width, and depth (see 6.3 and Fig. 1 and Fig.

15).

FIG. 11 Box, Fiberboard; SFF—Special Full Flap Slotted Box (0206)

FIG. 12 Box, Fiberboard; CSSC—Center Special Slotted Box and CSOSC—Center Special Overlap Slotted Box (0205)

FIG. 13 Box, Fiberboard; HSCC—Half Slotted Box with Cover (0200)

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6.2.1.2 Regular Slotted (RSC/0201)—This box shall meet

the requirements of Fig. 8. The box shall be scored and slotted to form a body piece having four flaps for closing each of two opposite faces. The flaps along the longer edge of the box openings are the outer flaps and those along the shorter edge are the inner flaps. Flaps shall not project beyond an edge of the box. All flaps shall be of equal width with the outer flaps meeting in the center of the width panel but shall not overlap.

The gap not to exceed 1⁄4 in. [6 mm] will be permitted unless otherwise specified.

6.2.1.3 Overlap Slotted (OSC/0202)—This box shall meet

the requirements of Fig. 9. This box shall be scored and slotted to form a body piece having four flaps for closing each of two opposite faces. When closed, the inner flaps shall not overlap and the outer flaps shall overlap the distance specified (see 8.1.9). Inner flaps shall be the same width as the outer flaps, except where the relation of width to length would cause the inner flaps to overlap, in which case, the inner flaps shall be cut so that, when in closed position, they shall meet.

6.2.1.4 Full Overlap Slotted (FOL/0203)—This box shall

meet the requirements of Fig. 10. The box shall be constructed in accordance with 6.2.1.3, except that the width of the outer flaps shall be the full width of the box and shall not extend beyond the edge of the box (see 6.6).

6.2.1.5 Special Full Flap Slotted (SFF/0206)—This box

shall meet the requirements of Fig. 11. This box shall be constructed in accordance with 6.2.1.3, except that the width of the inner flaps in the closed position shall be such that they meet in the center of the box but do not overlap. A gap not to exceed 1⁄4 in. [6 mm] will be permitted.

6.2.1.6 Center Special Slotted (CSSC/0204)— This box

shall meet the requirements of Fig. 12. The box shall be constructed in accordance with 6.2.1.2, except that the width of the inner and outer flaps shall be such that they meet in the center of the box but do not overlap. A gap not to exceed 1⁄4 in.

[6 mm] will be permitted.

6.2.1.7 Center Special Overlap Slotted (CSOCS/0205)—

(See Fig. 12.) This box shall be as specified herein. When closed, the inner flaps shall meet in the middle of the face with a gap not to exceed 1⁄4 in. [6.4 mm] when in the closed position.

Outer flaps shall be the same width as the inner flaps and may overlap (no flap cutting is required). Dimension of the box shall be such that the outer flaps do not extend beyond the configuration of the box.

6.2.1.8 Half Slotted With Cover (HSCC/0312)—This box

shall meet the requirements of Fig. 13. The box consists of a box body and a cover. The body shall be scored, slotted and secured to form a tube having four flaps, of equal width on the bottom. The outer flaps shall meet when closed with a gap not to exceed 1⁄4 in. [6.4 mm]. Unless otherwise specified, the cover shall be a Type I (see Fig. 5) stitch locked cover. When specified (see 8.1.5), the cover shall be Type II (see Fig. 5).

Unless otherwise specified, (see 8.1.11 and 8.1.12) the cover depth shall be 3 in. [76 mm] and shipped unassembled. The body may be used as an HSC alone.

6.2.1.9 Double Cover (DBLCC/0310)—This box shall meet

the requirements of Fig. 14. The box consists of a body tube and two covers. The body consists of fiberboard, scored and secured to form a tube having parallel ends. Unless otherwise specified, the covers shall be Type I (see Fig. 5) stitch lock covers, 3 in. [76 mm] deep. When specified (see 8.1.10 and 8.1.11), the cover shall be Type II (see Fig. 5), and the cover or covers of any type may be other than 3 in. [76 mm] in depth.

Unless otherwise specified (see 8.1.12), the cover shall be unassembled.

6.2.1.10 Interlocking Double Cover (IC/0325)—This box

shall meet the requirements of Fig. 15. The box consists of a body tube with top and bottom flanges and two interlocking covers. The box body shall be fiberboard (SW or DW) scored, slotted, and secured to form a tube having double scored short flanges (flaps) which form a lock with the flanges of the cover.

The top and bottom covers shall be Type III (see Fig. 5) flange interlock covers and shall be secured by means of horizontal straps. Unless otherwise specified, (see 8.1.3) the flanges shall be 3 in. [76 mm] long for boxes made of variety SW fiberboard and 4 in. [102 mm] long for boxes made of variety DW fiberboard.

6.2.1.11 Full Telescope (FTC/0301)—This box shall meet

the requirements of Fig. 16. The box consists of a body and a

FIG. 14 Box, Fiberboard; DBLCC—Double Cover (0310)

FIG. 15 Box, Fiberboard; IC—Interlocking Double Cover (0325)

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Not for Resale, 02/20/2009 08:19:46 MSTNo reproduction or networking permitted without license from IHS cover, each constructed of one piece of fiberboard, scored and slotted. The box dimensions shall be the inside measurements of the assembled box body. The cover shall be a snug fit on the body. When specified, flaps shall be positioned inside the side panels of the body and inside the end panels of the cover or inside the side panels of the body and outside the end panels of the cover (see 8.1.15). When set up, the flaps shall not overlap but shall be of sufficient length to allow them to be securely fastened to the adjoining walls by one of the following means:

(1) With not less than five staples applied per flap illus-trated in Fig. 5. The edge flaps on the body and cover (see Fig.

5) shall not protrude more than 1⁄4 in. [6 mm] beyond the edge of the member to which it is secured. Fastening along the free edges shall be not more than 4 in. [102 mm] apart.

(2) The flaps, when specified (see 8.1.14) shall be securely glued together with adhesive specified in 6.1.2.1 and 6.1.2.2 covering a minimum of 50 % of the area.

(3) The flaps and adjoining walls may be die cut to allow them to be fastened securely to the adjoining wall with a snap-together tongue or tuck lock corner without causing the fiberboard to rupture.

(4) Unless otherwise specified (see 8.1.15), the flaps on the body and cover shall be positioned in one of the following combinations, at the option of the supplier:

(a) Flaps outside the side panels of the body and inside the end panels of the cover.

(b) Flaps outside the end panels of the body and inside the side panels of the cover.

(c) For snap-together or tuck lock corner, the flaps shall be outside the end panels of the body and outside the side panel of the cover.

When specified (see 8.1.12), flaps shall be inside the side panels of the body and outside the end panels of the cover.

Unless otherwise specified (see 8.1.12), the body and cover shall be shipped unassembled.

6.2.1.12 Full Telescope Half Slotted Box (FTHS/0320)—

This box shall meet the requirements of Fig. 17. The box consists of a body and a telescoping cover, each constructed of one piece of scored and slotted fiberboard. The box dimensions shall be the inside measurements of the assembled box body.

The cover shall be a snug fit on the body. The flaps along the longer edge of the box openings are the outer flaps and those along the shorter edge are the inner flaps. Flaps shall not project beyond an edge of the box. All flaps shall be of equal width with the outer flaps meeting in the center of the box but shall not overlap. A gap not to exceed 1⁄4 in. [6 mm] will be permitted unless otherwise specified.

6.2.1.13 One Piece Folder (OPF/0401)—This folder shall

meet the requirements of Fig. 18. The folder shall be con-structed of one piece of fiberboard, scored and slotted as indicated in the referenced figure. When closed, outer flaps shall meet. A gap not to exceed 1⁄4 in. [6 mm] will be permitted.

Unless otherwise specified, the inner flaps shall not be less than 2 in. [51 mm] long for folders under 18 in. [457 mm] in width and not less than 3 in. [76 mm] long for folders 18 in. [457 mm] and over in width.

6.2.1.14 Five-Panel Folder (FPF/0410)—This folder shall

meet the requirements of Fig. 19. The folder shall be scored and slotted as indicated in the referenced figure. When set up, outer flaps shall overlap (full overlap). The tuck flap length (see Fig. 19, width) shall be equal to the length of the side panel (see Fig. 19, width) less 1⁄4 in. [6 mm] 6 1⁄8 in. [3 mm].

FIG. 16 Box, Fiberboard; FTC—Full Telescope (0301)

FIG. 17 Box, Fiberboard; FTHS—Two Piece Full Telescope Half Slotted Box (0320)

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6.2.1.15 Rigid Box (Bliss Box/0600 Series)—This box shall

meet the requirements of Fig. 20. The three pieces of a rigid box style include two identical end panels and a body that folds to form the two side panels, an unbroken bottom, and the top.

Flaps used to form the joints can be on the end pieces or the body or both. The end panels are attached to the body with speical equipment, usually at the user’s plant. Six or more joints must be sealed to set up the box before it is filled. The name Rigid Box comes from the fact that once the six or more joints are sealed, the box is rigid.

6.2.1.16 Tongue and Slot Closure (TSC)—This box shall

meet the requirements of Fig. 21. The box shall be constructed of one piece of fiberboard, scored and slotted as indicated in the referenced figure.

6.2.1.17 Triple Slide (TS)—This box shall meet the require-

ments of Fig. 22. The box shall be constructed of three pieces of fiberboard scored to provide three tubes that, when as-sembled, completely cover six faces of the box. The inner tube shall be left open as illustrated, the middle tube shall be taped at the body joint and shall be a sliding fit on the assembled inner tube, the outer tube shall be taped at the body joint and shall be a sliding fit on the assembled inner and middle tubes.

The box dimensions shall be the inside dimensions of the inner tube in the sequence of length, width, and depth, and shall be as illustrated in the referenced figure. Corrugations shall be at right angles to the scoreline in each tube.

6.2.2 Reinforcements:

6.2.2.1 Sleeves—When specified (see 8.1.5) sleeves shall be

constructed from fiberboard as specified in 6.4.1.2. If butt joint, it may be taped, or the overlap joint may be stapled, stitched or glued (see Fig. 3). Alternatively, the location of the body joint shall be in the center of the top or bottom panel, providing the joint does not interfere with the required marking. The sleeve shall fit closely over the top, bottom and end panels of the box

FIG. 18 Folder, Fiberboard; OPF—One Piece Folder (0401)

FIG. 19 Folder, Fiberboard; FPF—Five Panel Folder (0410)

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Not for Resale, 02/20/2009 08:19:46 MSTNo reproduction or networking permitted without license from IHS for which it is intended. Space between the sleeve and box shall not exceed 3⁄16 in. [5 mm] when opposite surfaces of sleeve and box are in direct contact with each other.

6.2.2.2 Liners—When specified (see 8.1.6), liners shall be

constructed from fiberboard as specified in 6.4.1.3 and 6.4.2.2 (see Fig. 7). The liner shall be scored to cover the end and side panels of the box for which it is intended. The flutes of the liner shall be perpendicular to the top of the box. Unless otherwise specified (see 8.1.16), the height of the liner shall be the full inside depth of the box for which intended, and the ends of the liner shall abut (gap not to exceed 1⁄8 in. [3 mm]) in the center of a side panel of the box.

6.3 Dimensions—Box dimensions shall be as specified in

the contract or order (see 8.1.17). The dimensions shall be the inside measurements and shall be cited in the sequence of length, width, and depth (see Fig. 1). Use of Test Method D 2658 is recommended for determining inside dimensions.

The length dimension shall be the larger of the two dimensions of the open face of the box or folder; the width dimension shall be the lesser dimension of the open face of the box or folder;

the depth dimension shall be the distance between the inner-most surfaces of the box or folder measured perpendicular to the length and width. Unless otherwise specified, a tolerance of 61⁄8 in. [3 mm] shall be permitted in each overall dimension of the box, when conditioned according to Method D 685. When boxes are ordered complete with sleeves, for example, RSC- SL, the fit shall be as specified in 6.2.2.1. When boxes are ordered complete with liners, for example, RSC-L, the liners shall fit snugly inside the box.

6.3.1 Size and Weight Limits—Unless otherwise specified, (see 8.1.4) size and weight limitations of boxes furnished under this specification shall be in accordance with Tables 1-3.

Boxes, folders, sleeves, or liners shall be made from one piece of fiberboard, except that when the length of the box blank (two lengths plus two widths plus manufacturer’s joint) ex-ceeds the largest fiberboard sheet length available to the manufacturer, two pieces of fiberboard may be used provided that the manufacturer’s joints are placed at diagonally opposite corners.

6.4 Construction of Boxes, Sleeves, and Liners:

6.4.1 Type CF and SF, Class Weather-Resistant and WWVR

Boxes—Unless otherwise specified (see 8.1.7), type CF or SF, class weather-resistant and WWVR boxes shall be of style (see 6.2.1), material (see 6.1.1), dimensions (see 6.3), and grade of fiberboard (specified in Table 3). Variety SW fiberboard used to fabricate type CF boxes shall be either A, B, or C flute, as specified (see 8.1.2). Variety DW fiberboard used to fabricate type CF boxes may be any combination of A, B, C, or E flutes, or as otherwise specified. Conventional slotted, type CF, variety SW or DW boxes shall have the flutes running perpendicularly to the scoreline of the box opening, unless otherwise specified (see 8.1.18). When specified (see 8.1.18), end loading, conventional slotted, type CF, variety SW or DW boxes shall have the flutes running parallel to the scoreline of the box opening. The flutes in DBLCC (see 6.2.1.9) and IC (see 6.2.1.10) boxes shall run the depth of the box perpendicular to the openings.

6.4.1.1 Manufacturer’s Joint, Class Weather-Resistant and

WWVR Boxes (see Fig. 2)—The joint of type CF and SF boxes

FIG. 20 Box, Fiberboard; Rigid Box–Bliss Box (0606)

FIG. 21 Folder, Fiberboard; TSC—Tongue and Slot Closure

FIG. 22 Box, Fiberboard; TS—Triple Slide Box

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Not for Resale, 02/20/2009 08:19:46 MSTNo reproduction or networking permitted without license from IHS shall be a fiberboard overlap not less than 11⁄2 in. [38 mm] wide extending the full inside depth of the box. The joint tab may be an extension of either the end or side panel of the box and shall not extend beyond the top and bottom scorelines of the adjoining panel. The joint shall be fastened either inside or outside the adjoining panel, and the top and bottom edges of the joint tab shall be not more than 3⁄16 in. [5 mm] below the top scoreline or 3⁄16 in. [5 mm] above the bottom scoreline of this panel. When specified, the inside joint tab may extend into the flap area and be secured (see 8.1.19). Except as specified in

6.4.1.1 (1), the overlapped joint shall be secured with adhesive specified in 6.1.2.1 and 6.1.2.2 except the toxicity requirements may be waived when packing items other than food that may

TABLE 1 Size and Weight Limitations for Types CFA and SFA Class Domestic Fiberboard BoxesB

(Specified by Bursting Strength–Mullen Test)

Type CF Variety Type SF

Combined Weight Facings Only, min.

(SF is total weight of plies)

Max Weight of Boxes and Contents

Max Outside Dimensions Length + Width + Depth

SWA DWA lb/1000 ft.2(g/m2)

Grade Grade Grade lb [m2] lbs [kg] in. [mm]

125 52 [254] 20 [9.1] 40 [1016] 125 114 [557] 20 [9.1] 40 [1016]

150 66 [322] 35 [15.9] 50 [1270] 175 75 [366] 50 [22.7] 60 [1524]

175 149 [727] 40 [18.2] 60 [1524] 200 84 [410] 65 [29.5] 75 [1905]

200 92 [449] 80 [36.3] 85 [2159] 200 190 [928] 65 [29.5] 75 [1905]

250 111 [542] 80 [36.3] 85 [2159] 275 138 [674] 95 [43.1] 95 [2413]

275 110 [537] 100 [45.4] 95 [2413] 275 237 [1157] 90 [40.8] 90 [2286]

350 180 [879] 120 [54.4] 105 [2667] 350 126 [615] 120 [54.4] 105 [2667]

350 283 [1382] 120 [54.4] 100 [2540] 400 180 [879] 140 [63.5] 110 [2794] 500 222 [1084] 160 [72.6] 115 [2921]

500 330 [1611] 140 [63.5] 110 [2794] 600 270 [1318] 180 [81.6] 120 [3048]

600 360 [1758] 160 [72.6] 120 [3048] AExplanation of abbreviations in Table 1:

CF—Corrugated Fiberboard SF—Solid Fiberboard SW—Singlewall Fiberboard DW—Doublewall Fiberboard BSize and weight limitations may be modified or waived by the ordering activity, as necessary, when boxes are used for non-shipper or special purposes.

TABLE 2 Size and Weight Limitations for Types CFA Class Domestic Fiberboard BoxesB

(Specified by ECT)

Type CF Variety Max Weight of Box and Contents

Max Outside Dimensions

Length + Width + DepthSWA DWA

ECT

Grade

ECT

Grade lbs [kg] in. [mm]

23 20 [9.1] 40 [1016] 26 35 [15.9] 50 [1270] 29 50 [22.7] 60 [1524] 32 65 [29.5] 75 [1905] 40 80 [36.3] 85 [2159] 44 95 [43.1] 95 [2413] 55 120 [54.5] 105 [2667]

42 80 [36.3] 85 [2159] 48C 100 [45.4] 95 [2413] 51C 120 [54.5] 105 [2667] 61C 140 [63.6] 110 [2794] 71C 160 [72.6] 115 [2921] 82C 180 [81.7] 120 [3048]

AExplanation of abbreviations in Table 2:

CF—Corrugated Fiberboard SF—Solid Fiberboard SW—Singlewall Fiberboard DW—Doublewall Fiberboard BSize and weight limitations may be modified or waived by the ordering activity, as necessary, when boxes are used for non-shipper or special purposes.

CValues subject to confirmation.

TABLE 3 Size and Weight Limitations for Class Weather- Resistant [WR] and Water and Water Vapor Resistant [WWVR]

Fiberboard Boxes Used as Exterior ContainersA

NOTE 1— The gross weight and size limit expressed in the circular or rectangular boxmaker’s certificate shall conform to the requirements of the National Railroad Freight Commission or National Motor Freight Classification Rules, as applicable, and may not necessarily be the same as those stipulated in Table 3. To meet the Practice D 5118 V or W requirements for WWVR and WVR board, boxes will have lower weight and smaller maximum size requirements than are shown in Table 1 and Table 2.

GradeB [Compliance Symbol]

Max Weight of Boxes and Contents

Max Inside Dimensions Length + Width + Depth lb [kg] in. [mm]

V2s 120 [54.4] 100 [2540] V3s, V4s, and V3c 90 [40.8] 90 [2286] W5s and W5c 65 [29.5] 75 [1905] W6s 30 [13.6] 30 [762] V11c 160C [72.6] 120 [3048] V13c 120 [54.4] 100 [2540]

ANot applicable to interior boxes.

BReference Specification D 4727 for specific details of construction.

C Maximum weight may be increased to 225 lb [102 kg] provided the manufac-turer’s body joint is fastened with metal fasteners spaced not more than 1 in. [25 mm] apart [see 8.1.8].

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Not for Resale, 02/20/2009 08:19:46 MSTNo reproduction or networking permitted without license from IHS contact the adhesive. The adhesive shall cover 85 % of the area between the joint tab and adjoining panel with a minimum of 75 % fiber tear of the total overlap area of cold or hot adhesive.

(1) Metal Fastener Manufacturer’s Joint—Alternatively, the joint for grades W5c, W5s, W6s, and V3c boxes may be secured with metal fasteners specified in 6.1.2.3. The metal fasteners shall be spaced not more than 2 in. [51 mm] apart, center to center, and the distance between the ends of the joint and the nearer end of the fastener shall not exceed 1 in. [25 mm]. An additional metal fastener (tie stitch) shall be placed 1⁄4

in. [6 mm] to 3⁄4 in. [19 mm] from each end of the joint. Tie stitches will not be required, provided the joint is fastened with the same total number of fasteners required (including tie stitches) equally spaced on not more than 2 in. [50.0 mm] centers with the distance between the outer fasteners and the ends of the joint not exceeding 1 in. [25 mm].

(2) Butted Manufacturer’s Joint—When specified (see 8.1.20), the joint of W5c boxes shall be made by butting the panels closely together and securing them with tape. The tape shall be a minimum of 2 in. [50.8 mm] wide, and affixed to the outside surface of the joint. The tape shall be centered 61⁄4 in.

[6 mm] on the joint, extend full depth, or within 3⁄8 in. [10 mm] of full depth, and shall adhere over not less than 90 % of area of contact.

6.4.1.2 Sleeves of Class Weather-Resistant and WWVR

Boxes—Sleeves for class weather-resistant and WWVR boxes shall be the design specified in 6.2.2.1 and fabricated from class weather-resistant and WWVR fiberboard of the same type and grade as the box for which it is intended. Sleeves fabricated from type CF fiberboard shall have the flutes parallel to the scores. Overlap joints shall be formed in the same manner as in 6.2.2.1.

6.4.1.3 Liners for Class Weather-Resistant and WWVR

Boxes—Liners for class weather-resistant and WWVR boxes shall be of the design specified in 6.2.2.2, unless otherwise specified, (see 8.1.22) shall be fabricated from material con-forming to Specification D 4727 grades W5c, V3c or V13c.

Unless otherwise specified, (see 8.1.21) the abutting ends shall be taped, at least three quarters the length of the joint, with tape at least 2 in. [51 mm] wide conforming to 6.1.2.4 (1). The tape shall adhere over not less than 90 % of the area of contact and shall be centered on the joint. Liners fabricated from type CF, variety SW fiberboard shall be A or C flute, and liners fabricated from type CF, variety DW fiberboard shall be any combination of A, B, C, or E flutes, or as otherwise specified.

When boxes are ordered complete with liner, the dimensions as stated in the contract or order will be the dimensions of the box (see 6.3). The dimensions of the liner shall be such that the liner shall fit snugly (see 6.2.2.2) inside the box. When specified (see 8.1.21), the liner joint shall be affected by overlapping and fastening with adhesive, as specified for type CF box joints in 6.4.2.1 (1) or 6.1.2.1.

6.4.2 Type CF and SF, Class Domestic Boxes—Unless

otherwise specified, (see 8.1.7) type CF and SF, class domestic boxes shall be of the style (see 6.2.1), material (see 6.1.1 and 8.1.2), dimensions (see 6.3) and grade of fiberboard specified in Table 1 or Table 2. Variety SW fiberboard used to fabricate Type CF boxes shall be A, B, C, or E flute. Variety DW fiberboard used to fabricate type CF boxes may be a combi-nation of A, B, C, or E flutes, or as otherwise specified. Type CF boxes shall have flute direction as specified in 6.4.1. The manufacturer’s joint of the boxes shall be formed and secured in accordance with 6.4.2.1.

6.4.2.1 Manufacturer’s Joint, Class Domestic Boxes, (see

6.1.2)—The joint of the type CF, variety SW box shall be overlapped or butted. The joint of the type SF, shall be overlapped. The joint of the type CF, variety DW box, shall be overlapped or butted. The formed joint shall be secured as specified in 6.4.2.1 (1) or 6.4.2.1 (2), as applicable. Large boxes (see 6.3.1) may be fabricated with two joints positioned at diagonally opposite corners at the option of the supplier.

(1) Overlapped Joint (Joint Tab)—The joint shall be made with a fiberboard joint tab overlap not less than 11⁄4 in. [32 mm] wide with the length of the overlap equal to the inside depth of the box. The joint tab may be an extension of either the end or side panel of the box. When specified, (see 8.1.19) the joint tab may extend into the flap area and be secured. The joint tab shall be fastened either inside or outside the adjoining panel, and the top and bottom edges of the overlap shall be no more than 3⁄16

in. [5 mm] below the top scoreline or 3⁄16 in. [5 mm] above the bottom scoreline of this panel. The overlapped joint of type CF boxes shall be fastened with adhesive as specified in 6.1.2.1 or 6.1.2.2, except the toxicity requirement may be waived when packing items other than food that may contact the adhesive, or with metal fasteners. When adhesive is used it shall be applied so as to cover the full area between the joint tab and the adjoining panel. The adhesive shall substantially extend to all edges of the overlap. The overlapped joint of type SF boxes shall be fastened with metal fasteners as specified in 6.1.2.3 and 6.4.2.1 (1). Metal fasteners for the type CF and type SF boxes having a depth dimension of 18 in. [457 mm] or less shall be spaced not more than 3 in. [76 mm] apart, center to center. Metal fasteners for the type SF box having a depth dimension greater than 18 in. [457 mm] shall be spaced not more than 21⁄2 in. [64 mm] apart, center to center. The distance between the ends of the joint and the nearer end of the nearest fastener shall not exceed 1 in. [25 mm]. Metal fasteners may be applied diagonally, vertically, or horizontally at the option of the supplier.

(2) Butted Joint (Type CF) Boxes Only—The butted joint shall be made by fitting the edges of the panels to be joined closely together and securing them with gummed tape. Tape used to secure the body joint of boxes having a gross weight of 40 lb [18 kg] or less (grade 125 to 175) shall be that normally used by the industry for this purpose (see 6.1.2.4 (1)). Tape used to secure the joints of boxes having a gross weight of more than 40 lb [18 kg] (grades over 175) shall be reinforced with sisal, cloth, glass, rayon or double strand nylon fibers (see

6.1.2.4 (2)). The tape shall be not less than 2 in. [51 mm] in width for boxes having a gross weight of 65 lb [30 g] or less (grade 200 and below) and not less than 3 in. [76 mm] in width for boxes having a gross weight over 65 lb [30 kg] (grade above 200). The tape shall be centered on the joint and shall extend its full length, or within 3⁄8 in. [10 mm] of full length and shall adhere over not less than 90 % to the entire area of contact with the fiberboard.

D 5118/D 5118M – 05ae1

13Copyright ASTM International Provided by IHS under license with ASTM Licensee=Federal Prison Industry/Unicor/8842475001

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6.4.2.2 Liners for Class Domestic Boxes— Unless other-

wise specified (see 8.1.22), liners shall be constructed of fiberboard material conforming to Specification D 4727, type CF, class domestic, variety DW, grade 275. The liners shall be designed, as specified in 6.4.1.3. Liners for class domestic/fire retardant boxes shall be class domestic/fire retardant.

6.5 Compliance Marking:

6.5.1 Types CF and SF, Class Weather-Resistant and WWVR

Boxes—Types CF and SF, class weather-resistant and WWVR boxes made to comply with this specification shall be im-printed with the following data which will legibly occupy a total area of not more than 36 in.2 [232 cm2] nor less than 16 in.2 [103 cm2] (see Fig. 4):

6.5.1.1 Boxmaker’s name or boxmaker’s certificate (refer

to NMFC and NRFC regulations).

6.5.1.2 Month and year of manufacturer (for example, “6-87”).

6.5.1.3 Individual grade or identification symbols.

6.5.1.4 For shipments to Government agencies the national

stock number (NSN), inside dimensions, and outside cube shall be marked below the specification data on all exterior type boxes procured as an item of supply. When filled boxes are procured for direct shipment to the Government, the supple-mental requirements set forth in Section 9 shall apply.

6.5.1.5 For class weather resistant/fire retardant boxes, the words “Fire Retardant” shall be marked below the box maker’s certification.

6.5.2 The above markings shall be located as follows:

6.5.2.1 Slotted Style Boxes—On the outer flap in a corner as

close to the scoreline as practicable.

6.5.2.2 All Other Styles—In a corner of the top panel as

close to the scoreline as practicable. Unless otherwise specified (see 8.1.23), no other marking shall appear on the box. The boxmaker’s certificate does not relieve the supplier of his responsibility for meeting the requirements of this practice.

6.5.2.3 When the box panel is not large enough to accom-

modate all of the markings, the markings may cross the scoreline (see 6.5.3).

6.5.3 Types CF and SF, Class Domestic Boxes—Each box

shall be plainly marked with the appropriate boxmaker’s certificate signifying compliance with the Uniform Freight Classification rules, and the National Motor Freight Classifi-cation rules, as applicable. The certificate may be located on the box wherever it is customarily placed; however, the preferred location is on the bottom panel or bottom outer flap.

The certificate on boxes having a length of less than 10 in.

[254.0 mm] or width of less than 9 in. [228.6 mm] may be reduced in size but the outside diameter shall not be less than 2 in. [50 mm]. In the event the box panel is too small to accommodate even the reduced certificate of compliance, the certificate will be permitted to cross the scoreline and cover more than one panel. For class domestic/fire retardant boxes, the words FIRE RETARDANT shall be marked below the boxmaker’s certificate. Unless otherwise specified (see 8.1.23), boxes will require no further markings. When specified (see 8.1.23), the specification number, dimensions, and cube shall be marked below the boxmaker’s certificate.

6.6 Workmanship—The completed box shall be clean, free

of frayed or torn edges, improperly aligned panels, improper scores and slots, and the marking shall be clear and legible. All dimensions of the boxmaker’s blank shall be accurately cut, scored, and slotted so that the assembled box parts fit closely without binding. No flap shall project beyond an edge of the box by more than 1⁄8 in. [3 mm] when the box is set up and closed. All metal fasteners shall be well clinched, flush with or below the interior and exterior surfaces of the corrugated fiberboard joined, and shall be flush or slightly above the surfaces for solid fiberboard.

7. Assembly of Class Domestic Boxes

7.1 Slotted Styles—All slotted style boxes shall be as-

sembled in accordance with the figures referenced herein. For closure of boxes the use of Practice D 1974 is recommended.

7.1.1 Slotted Styles With Covers—All slotted style boxes

with covers shall be assembled in accordance with the figures referenced herein.

7.1.1.1 Type I Cover (Stitch Lock)—The type I cover end

flaps (see Fig. 5) shall be securely fastened to the inside of the adjoining side flange by not less than three metal fasteners located not more than 11⁄4 in. [32 mm] nor less than 1⁄2 in. [13 mm] by not less than three stitches located not more than 0.47

in. [12 mm] from free edges and scorelines. Metal fasteners shall conform to 6.1.2.3. When specified the flaps may be joined with adhesives detailed in 6.1.2.1, 6.1.2.2, and 6.4.1.1.

See 8.1.24.

7.1.1.2 Type II Cover (Friction Lock)— The type II cover

end flanges B and C (see Fig. 5) shall be slightly wider than the side flanges “A” of the cover in order to produce a friction lock. Metal fasteners shall not be used to assemble these covers.

7.1.1.3 Type III Cover (Flange Interlock)— All interlocking

flange boxes shall be assembled in accordance with the referenced figures herein. The interlocked flanges shall be secured by means of flat steel strapping applied horizontally one band width above the center line of the fold (see Fig. 5).

The strapping shall be not less than 3⁄8 in. [9.5 mm] by 0.015

in. [0.38 mm], finish A or B, grade 2, as specified in Specification D 3953 or Type IV polyester plastic strapping specified in Specification D 3950.

7.1.2 Style FTC—All body and cover flaps shall be fastened

to the adjoining walls, as illustrated in Fig. 16.

7.2 Assembly of Class Weather-Resistant and WWVR Boxes:

7.2.1 Slotted Styles with Covers—Slotted style boxes shall

be assembled in accordance with the figures referenced herein.

7.2.2 Style FTC—Body and cover flaps of style FTC boxes

shall be securely fastened to the adjoining walls (see 6.2.1.11).

8. Ordering Information

8.1 Purchasers should select the preferred options permitted

herein, and should include the following information in pro-curement documents:

8.1.1 Title, number and date of this practice.

8.1.2 Type, class, variety, and grade of fiberboard (see 6.1.1,

6.4.1 and 6.4.2).

8.1.3 Box style required (see 5.1, 5.2 and 6.2.1).

8.1.4 Size and weight limitations of boxes (see 6.3.1).

D 5118/D 5118M – 05ae1

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Not for Resale, 02/20/2009 08:19:46 MSTNo reproduction or networking permitted without license from IHS

8.1.5 When sleeve is required (see 6.2.2.1 and 6.4.1.2).

8.1.6 When liner is required of SW or DW fiberboard and

grade of fiberboard required (see 6.2.2.2 and 6.4.1.3).

8.1.7 When box is for special requirements (see 6.4.1 and

6.4.2).

8.1.8 When maximum requirements for V11c boxes may be

increased (see Table 3).

8.1.9 Distance of overlap for OSC boxes (see 6.2.1.3).

8.1.10 When type II cover is required for HSC and DBLCC

boxes (see 6.2.1.8 and 6.2.1.9).

8.1.11 Depth of cover other than 3 in. [76.2 mm] for HSC

and DBLCC boxes (see 6.2.1.8 and 6.2.1.9).

8.1.12 When covers and bodies are to be shipped assembled

(see 6.2.1.8, 6.2.1.9 and 6.2.1.11).

8.1.13 Length of flange for IC boxes, if other than specified

(see 6.2.1.10).

8.1.14 When glued flaps of FTC are permitted (see

6.2.1.11).

8.1.15 When flaps of the FTC box are required to be

arranged in a manner other than that specified (see 6.2.1.11).

8.1.16 When the ends of the liner shall abut in other than the center of the side panel of the box (see 6.2.2.2).

8.1.17 Inside dimensions of box, specified in inches, in

order of length, width and depth (see 6.3).

8.1.18 When the direction of flutes is to run parallel to

scoreline of box opening (see 6.4.1).

8.1.19 When the manufacturer’s joint tab may extend into

the flap area (see 6.4.1.1 and 6.4.2.1 ( 1)).

8.1.20 When taping of manufacturer’s joint is permitted for

W5 and W6 boxes (normally for interior boxes) (see 6.4.1.1 (2)).

8.1.21 When liner joints secured with other than tape (see

6.4.1.3).

8.1.22 When other variety or grade fiberboard is required

for liners (see 6.4.1.3 and 6.4.2.2).

8.1.23 Printing and marking required in addition to certifi-

cation (see 6.5.1, 6.5.3, and 9.3).

8.1.24 When other methods of sealing cover assembly joints

are required (see 7.1.1.1).

9. Preparation for Delivery

9.1 Unless otherwise specified, packing and marking shall

be in accordance with Practice D 3951.

9.2 For delivery to agencies of the U.S. Government, packing shall be as specified in the contract or order.

9.3 Marking for Delivery to U.S. Government Agencies (See

8.1.23):

9.3.1 Civil Agencies—In addition to any special marking

required by the contract or order, shipping containers shall be marked in accordance with FED-STD-123.

9.3.2 Military Requirements—In addition to any special

marking required by the contract or order, shipping containers shall be marked in accordance with MIL-STD-129.

10. Keywords

10.1 boxes; box fabrication; box styles; fiberboard

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