Low Lignin Document Storage Box

June 1993

Scope

This specification covers the requirements for a document storage box which is one piece, shipped flat, self locking, and made from low lignin corrugated board.

Requirements

Construction

The shipped flat clam shell box shall consist of one B- or E-flute corrugated singlewall (double-faced) board, comprised of two facings (liners) adhered to one fluted medium with fluting running perpendicular with the spine of the box as indicated in [Figure 1-1]. Assembly shall be self locking. Assembly shall not include adhesive or metal fasteners. Construction shall be such that the self locking walls are double thickness and alternate, that is, when the box is closed, both side walls and front wall shall be double thickness. The self locking assembly shall be such that the tabs fit snugly into "U" shaped incisions cut in the top and bottom of the box. See [Figure 1.2], [Figure 1.3], and [Figure 1.4]. All fold lines are to be scored or crimped, with no perforations. When the paperboard is scored twice to assemble a double wall, the space between parallel scores shall not exceed two board thicknesses. A shallow thumb cut shall be centered on the outside foredge. The thumb cut shall not exceed 1/4" in height. See [Figure 1.1] and [Figure 1.2], [Figure 1.3], and Figure 1.4. The distance between the lower edge of the extension flaps at the spine and the tray of the box shall not be greater than 1/8". The spine of the box shall be cut so that it is flush with the side walls when the assembled box is closed. See [Figure 1.1] and [Figure 1.2], [Figure 1.3], and [Figure 1.4] (drawings are not to scale).

Dimensions

The dimensions of the box shall be specified in the contract as inside measurements in the following order: length, width, and depth with a tolerance of plus or minus 1/16"; and the specified maximum outside dimensions. All box sizes shall be constructed from the same corrugated board type.

Paperboard

Composition
All layers of the corrugated paperboard laminate shall be made from cotton or linen pulp, fully bleached chemical wood pulp, or a mixture. The paperboard shall be free of groundwood (ASTM D1030, X 5 Spot Stains and Tappi T-236cm-85), alum-rosin sizing (ASTM D549-88), particles of metal, waxes, plasticizers (i.e. wet strength additives), plastics, and shall contain less than 0.0008 percent reducible sulfur (Tappi T406cm-88). Surfaces shall be free of knots, shives, and abrasive particles.

Color
The color shall be gray or tan.

Sizing
Alkaline sizing (surface, internal, or both) shall be used (ASTM D4988-89).

Alkaline Reserve
The corrugated paperboard shall have a minimum of 3 percent calcium carbonate, magnesium carbonate, or a combination of both evenly distributed throughout all layers of the lamination, when tested according to ASTM D4988-89.

Hydrogen Ion Concentration (pH) (cold extraction method)
The pH value of the corrugated paperboard shall be between 8.0 and 10.0 when tested according to TAPPI T509cm-88.

Lignin
To demonstrate the adequacy of bleaching or lignin removal, all layers of the corrugated paperboard shall have a negative reading in the phloroglucinol test when tested according to ASTM D1030 or shall have a KAPPA number of 5 or less when tested according to TAPPI T-236cm-85.

Abrasion
Outer surface of the paperboard shall show a loss of less than 0.3 percent of the total weight (mounting card and sample) when tested with #CS 10 wheel and 100 wear cycles (TAPPI T-476om-91).

Surface Smoothness
(to determine the property of adhesion of a pressure sensitive label to the paperboard surface) The surface of the paperboard shall hold a piece of weighted pressure sensitive tape securely in place for at least 10 minutes in 6 out of 9 trials, when tested according to ASTM D286-90, Procedure B modified as follows:

-use 3M brand #810 3/4" wide, pressure sensitive tape to conduct the test
-adhere the tape to the paperboard surface with 2 rolls of a 10kg steel roller; allow samples to set 3 days before testing
-suspend a 2oz weight from the tape

Thickness
The corrugated paperboard thickness shall be no greater than 0.125 inches and no less than 0.115 inches for B-flute and no greater than 0.073 inches and no less than 0.062 inches for E-flute when tested according to TAPPI T-411 om-89.

Stiffness
The corrugated paperboard shall be tested for stiffness in accordance with TAPPI T489cm-92 except that for each specimen tested the corrugations shall run in the long direction of the specimen. Test conditions shall include 7.5 degrees deflection and a 5,000 Taber unit weight. The board shall have an average minimum stiffness of 3700 plus or minus 1000 Taber Stiffness Units for B-flute and 2600 plus or minus 1200 Taber Stiffness Units for E-flute. Collapse of the corrugating medium shall constitute failure.

Finish
The corrugated paperboard shall be smooth and free of knots, shives, and other abrasive particles. The paperboard shall be free of dirt, marks, stains, surface or edge damage, or other imperfections or contaminations which might affect the utility or appearance of the product.

Color Retention
Dyes used to color the paperboard shall show no bleeding when soaked in distilled water for 48 hours while held in direct contact with white bond paper. The board shall not show a loss or gain of more than 5 points of brightness after exposure in a Sunlighter II apparatus for 96 hours or a fadeometer for 36 hours, when tested according to TAPPI T-452cm-87.

Workmanship

Each box shall meet the requirements stated in this specification, shall be assembled in accordance with good commercial practice, and shall be free of imperfections that may affect its utility or aesthetic appearance.

Each box shall be made to the dimensions specified. When assembled, all panels shall fit closely without gaps or warping. All edges shall be cut straight and shall be smooth and even. The corners of the box shall be square. When assembled the top and bottom shall rest flat on a flat plane. When locked into place, the self locking sides shall remain in position. When closed the top and bottom shall fit snugly and remain closed. The completed box shall contain no surface dirt (smudges, fingerprints, and the like) and shall not be marred (dents, bumps, etc.) in any way.

The paperboard shall be scored evenly. Perforations along fold lines are not acceptable. Scores shall be continuous and deep enough to permit precise folding during assembly. When the paperboard is scored twice to assemble a double wall, the space between parallel scores shall not exceed two board thicknesses. All folded edges shall be free of fraying, cracks, and breaks. The lid shall be able to withstand repeated opening without cracking, splitting, fraying, or otherwise losing strength along the hinge.

Shallow thumb cut on outer foredge shall be smooth, centered, and symmetrical.

Paperboard fluting shall be perpendicular to the spine. (See Figure 1.)

Identification Markings

The following information shall be legibly embossed on the outside bottom of each box: name of manufacturer, pH range, year of manufacture, and the words low lignin.

Preparation for Delivery

Packaging

The document storage boxes shall be shipped flat in a standard commercial container that is sealed with tape. The number of knocked down boxes to be packed in each container shall be specified in the purchase order.

Marking

The outside of each packing container shall be legibly marked with the following information: the purchase order number and the size and number of document storage boxes packed in the container.

Quality Assurance Provisions

Tests

Test procedures and controls specified in this document shall be used to determine the quality of the product. Other procedures and controls must be approved by the National Archives before test results will be accepted. Unless otherwise indicated, the test shall be performed at and the samples conditioned to standard conditions of 73 degrees Fahrenheit (plus or minus 1.8 degrees) and 50 percent relative humidity (plus or minus 2 percent R.H.) See TAPPI T-402cm-88.)

Test Methods

The requirements for paperboard quality and characteristics shall be tested in accordance with specified test methods of the American Society for Testing and Materials (ASTM) and the Technical Association of the Pulp and Paper Industry (TAPPI); and the American National Standards Institute (ANSI).

Publications describing these tests may be ordered directly from the technical associations at the following addresses:

ANSI - American National Standards Institute, 1430 Broadway, New York, New York 10018

ASTM - American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103

TAPPI - The Technical Association of the Pulp and Paper Industry, One Dunwoody Park, Atlanta, GA 30348

Tests for Paperboard Quality

The requirements for paperboard quality shall be tested according to the following method:

Responsibility for Tests

Unless otherwise specified in the purchase order, the supplier is responsible for the performance of all requirements specified herein. Unless otherwise specified, the supplier may use his or her own facilities or any commercial laboratory acceptable to the National Archives. The National Archives reserves the right to perform any of the tests set forth in the specification where such tests are deemed necessary to assure that supplies and service conform to prescribed requirements.

InspectionExamination Criteria

An examination shall be made to determine whether the completed box complies with the Requirements section of this specification. The qualities and characteristics that shall be regarded as unacceptable in the completed box are listed below.

Shipped Flat Box

• Not style specified


• Not dimensions specified


• Not materials (qualities or characteristics) specified


• Not color specified


• Not construction specified


• Not identification markings specified

Workmanship

• Edges not cut straight, not smooth and even


• Scores not deep enough to permit precise folding during assembly


• Corners of the box, not square


• Box not capable of being opened repeatedly without cracking, splitting,

fraying, or otherwise losing strength along the hinge of the lid

• When folded, edges showing exterior splits and cracks


• Completed box warped and uneven on flat surface


• Lid bows open; not a snug fit


• Assembled box torques or twists when filled with documents


• Panels gape or bulge and are not aligned properly


• Surfaces not clean or smooth; smudges, fingerprints or dirt; not free of lumps or indentations


• Surfaces torn, scuffed, or otherwise physically marred


• Packaging for Delivery


• An examination shall be made to determine whether the packaging of the boxes for delivery comply with the requirements of Preparation for Delivery section of this specification. The characteristics that shall be regarded as unacceptable in the packaging are listed below.


• Not number of boxes per container specified in contract


• Container not sealed with tape


• Container not legibly marked with the purchase order number


• Container not legibly marked with number of document boxes within

Responsibility for Inspection

Unless otherwise specified in the purchase order, the supplier is responsible for the performance of all inspection requirements as specified herein. The National Archives reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

Sampling for Examination

Construction and Workmanship

To sample boxes for construction and workmanship, boxes shall be selected for an examination of construction and workmanship following sampling procedures described in MIL-STD 105E at inspection level S-2 with an acceptable quality level of 4.0 percent defective from each lot of material offered.

Testing

To sample boxes for testing, boxes shall be selected according to MIL-STD 105E at inspection level S-2 with an acceptable quality level of 2.5 percent defective from each lot of material offered.

Preparation for Delivery

To sample boxes for compliance with packaging and marking requirements, boxes shall be selected according to MIL-STD-105E at inspection level S-2 with an acceptable quality level of 4.0 percent defective from each lot of material offered.

Sampling Method

The sampling of boxes for examination shall be carried out according to methods specified in "Sampling Procedures and Tables for Inspection by Attributes", MIL-STD-105E, issued January 2, 1990 and available from Naval Publications and Forms Center; Standardization Document Order Department, Building 4, Section D; 700 Robbins Avenue; Philadelphia, Pennsylvania, 19111-5094.

Ordering Information

The following information shall be included in the purchase order:

Title and date of the specification

Purchase order number

Number of knocked down boxes per shipping container

Special delivery conditions

List of possible vendor sources

Archivart
Division of Heller and Usdan
7 Caesar Place
Moonachie, NJ 07074
1-800-333-4466
FAX: (201) 935-5964
Attn: Robert Stiff

Conservation Resources International Inc.
8000 H Forbes Place
Springfield, VA 22151
(703) 321-7730
FAX: (703) 321-0629
Attn: Bill Hollinger

Hollinger Corporation
P.O. Box 8360
Fredrichsburg, VA 22404
1-800-634-0491
Attn: Tom Mahoney

Light Impressions
439 Monroe Ave
Rochester, NY 14607-3717
1-800-828-9859

University Products
517 Main Street
P.O. Box 101
Holyoke, MA 01041-0101
1-800-762- 1165
FAX: 1 (413) 532-9281
Attn: David McGoon
1-800-628- 1912

Custom Manufacturing Inc.
P.O. Box 88
Germantown, MD. 20875
(717) 642-6253
Attn: Michael Waters