Low Lignin Microfilm Box

(for microfilm boxes to house the 1920 Census only)

April, 1991

Scope

This specification covers the requirements for an assembled low lignin microfilm box with reverse tuck-in, two-end side flaps, locking notches at the right side flap, a thumb notch on the left side of the back panel, and printing on the front and back panels. (See Figure 7-1.)

Requirements

Construction

The assembled box shall consist of one die cut paperboard box blank, cut and scored as indicated in Figure 7-1.

The box orientation shall be as follows:

1. front
   
2. back


3. top


4. bottom

The front of the box shall be extended to the left by a two-end flap, FG. The back of the box shall be extended to the right by a two-end flap IJ. Slits shall be made along lines MN, OP, and RQ so that scores can be made along lines MM, OO, and QQ. Scores shall also be made along lines LM and OQS at the left and LMOQ at the right. Additional scores shall be made along the side flaps at lines PP and TT. One half inch slits shall be made in from each end of line PP to form the interlocking notches at the right side flap. A thumb notch shall be centered at the left edge on the back of the box and shall measure 3/8 inch The corners of the outer segment of the right flap (J) and the left flap (G) shall be rounded. Junction flap E and segments K and H shall be tapered as shown in Figure 7-1.

Junction flap E shall be adhered to the inside of D so that the cut end of D is aligned evenly with score line S.

Dimensions

35mm microfilm
The exterior dimensions of a box to house 35mm microfilm shall measure 3 13/16 inches in height, 3 13/16 inches in width, and 1 5/8 inches in depth, plus or minus 1/16 inch. Junction flap E shall measure at least 5/16 inch.

16mm microfilm
The exterior dimensions of a box to house 16mm microfilm shall measure 3 13/16 inches in height, 3 13/16 inches in width, and 1 inch in depth, plus or minus 1/16 inch. Junction flap E shall measure at least 5/16 inch.

Paperboard

Composition
The paperboard for the box shall be made from cotton or linen pulp, fully bleached chemical wood pulp, or a mixture. The paperboard shall be free of groundwood (ASTM D 1030, 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 T-406om-88). It shall be free of any components that will cause the paperboard to fail the photographic activity test (ANSI IT9.2-1988, Section 5) Surfaces shall be free of knots, shives, and abrasive particles.

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

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

Hydrogen Ion Concentration (pH)
The pH value of the paperboard shall be between 8.0 and 10.0 when tested according to TAPPI T-509om-88.

Lignin
To demonstrate the adequacy of bleaching or lignin removal, all plies and layers of the paperboard shall give a negative reading to 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 surfaces of the paperboard shall show a loss of less than 0.7 percent of the total weight (mounting card and sample) when tested with #CS 10 wheel and 100 wear cycles (TAPPI T-476om-84).

Thickness
The paperboard thickness shall be 0.027 inches plus or minus 0.002 inches, when tested according to TAPPI T-411om-84.

Stiffness
The paperboard shall have an internal stiffness of at least 800 Tabor stiffness units in the machine direction and 250 Tabor stiffness units in the cross direction at 15 degrees deflection, when tested according to TAPPI T-489om-86.

Finish
The paperboard shall be plate finished (calendered) on both sides.

Color
The paperboard shall be colored light blue on the outside (with a Munsell color measurement of between 10BG 5/6 - 6.6 and white on the inside.

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-452om-87.

Adhesive
Water resistant adhesive shall be used to adhere D (the junction flap) to E (the bottom of the box). When aged in an oven at 50 degrees centigrade and 87 percent relative humidity, the adhesive shall not soften or run, but shall firmly and evenly adhere D (the junction flap) to E (the bottom of the box). The properties of the adhesive shall not detract from the properties of the paperboard (i.e. reduce the alkaline reserve, increase the percentage of sulfur, decrease the pH, decrease the folding endurance, or cause the paperboard to fail the photographic activity test, ANSI lT9.2-1988, Section 5.). The adhesive shall not be visible through or alter the color of the paperboard. If it is necessary to buffer the adhesive, the same buffer as in the paperboard (i.e. calcium carbonate, magnesium carbonate, or a combination of both) shall be used.

Printing Ink

The printing ink shall be dark blue, with a Munsell color measurement of 2.5PB 2/6. It shall be colorfast, non-bleeding, and non-acidic. Specifically, the ink shall show no bleeding when the printed paperboard is soaked in distilled water for 48 hours while held in direct contact with white bond paper. The ink shall not reduce the alkaline reserve nor decrease the pH of the paperboard.

Printed Matter

The following image and text shall be legibly printed in dark blue ink (with a Munsell color of 2.5PB2/6) on the front of the box (See Figure 7.2):

• The National Archives seal The seal shall measure 1 3/4 inches in diameter and shall be centered on the front of the box.


• 1920 CENSUS This text shall occupy an area 21/4 inches in width x 5/16 inch in height and shall be centered and positioned approximately 1/8 inch above the top of the seal.


• MICROFILM This text shall occupy an area 21/4 inches in width x 1/4 inch in height and shall be centered and positioned approximately 5/16 inch below the bottom of the seal.

The following text shall be legibly printed in dark blue ink (with a Munsell color of 2.5PB 2/6) on the back of the box:

• This microfilm has been reproduced by the National Archives and Records Administration from the highest quality master negatives available from the Bureau of the Census. The original film includes defects that affect the legibility of some frames.


• This text shall be centered and shall occupy an area 21/2 inches in width x 2 inches in height.

Workmanship

Each box shall meet the requirements stated in this specification, shall be constructed 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. All edges shall be cut straight and shall be smooth and even. All slits in the paperboard to facilitate scoring or to create notches shall remain intact and shall not tear inward as the box is used. The box shall contain no surface dirt (smudges, fingerprints, and the like) and no oozed adhesive and shall not be marred (dents, bumps, and the like) in any way.

The paperboard shall be scored and creased uniformly. Scores and creases shall be deep enough to permit precise folding during assembly. All folded edges shall be free of fraying, cracks, and breaks. The side flaps shall be able to withstand repeated opening without cracking, splitting, fraying, or otherwise losing strength along the folds. The corners of the outer segment of the right flap (J) and the left flap (G) shall be rounded. unction flap E and segments K and H shall be tapered as shown in Figure 1. In the assembled box, the corners of the box shall be square. The bottom of the box shall rest evenly on a flat plane. All panels shall fit closely without gaps or warping. Junction flap E shall be adhered to the inside of D so that the cut end of D is aligned evenly with score line S. Adhesive shall be uniformly applied to the appropriate surface to provide a firm, even attachment of all components. The thumb notch shall be centered at the left edge of the back of the box. The notch shall be shaped uniformly and shall be smooth and even at the edge. The printing on the front and back of the box shall be legible, sharp, clean, and uniform.

Preparation for Delivery

Packaging

The microfilm boxes shall be packed flat in a standard commercial container that is sealed with tape. The number of 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 type, size, and number of microfilm 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 tests shall be performed at and the samples conditioned to standard conditions of 73 degrees Fahrenheit (plus or minus 35 degrees) and 50 percent relative humidity (plus or minus 2 percent RH.) (See TAPPI T-402om-88.)

Test Methods

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

Requirements Test Method

Test for Photographic Activity

The microfilm box (paperboard and any adhesive used) shall pass the photographic activity test described in ANSI IT9.2-1988, Section 5.

Verification of Color Requirements

The color of the paperboard and the printing ink shall be verified using the Munsell Book of Color, Glossy Finish Collection, 1976.

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 services conform to prescribed requirements.

Inspection

Examination Criteria

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

Completed Box

• Not style specified


• Not dimensions specified


• Not materials (qualities or characteristics) specified


• Not color specified


• Not construction specified


• Not identification markings specified

• Edges not cut straight, not smooth and even


• Slits in the paperboard not capable of remaining intact over time


• Scores and creases not deep enough to permit precise folding during construction


• Corners of the outer segment of the right and left flaps not rounded


• Junction flap E and segments K and H not tapered as shown in Figure 1


• Corners of the closed box, not square


• Closed box warped and uneven on flat surface


• Box not capable of being opened repeatedly without cracking, splitting, fraying, or otherwise losing strength along the folds at the side flaps


• Folded edges showing exterior splits and cracks


• Side flaps bow open; not a snug fit


• Panels are gaped or bulged and are not aligned properly


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


• Surfaces torn, scuffed, or otherwise physically marred


• Printed matter not legible, sharp, cleanly, nor evenly printed


• The thumb notch not centered at the left edge of the back of the box; not uniform in shape; not smooth nor even at the edge

Packaging for Delivery

An examination shall be made to determine whether the packaging of the boxes for delivery complies 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 type of microfilm boxes within


• Container not legibly marked with size of microfilm boxes within


• Container not legibly marked with number of microfilm boxes within

Unless otherwise specified in the purchase order, the supplier is responsible for the performance of all inspection requirements 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 service conform to the prescribed requirements.

Sampling for Examination

Construction and Workmanship
To sample boxes for construction and workmanship, 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.

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 defective from each lot of material offered.

Sampling Method
The sampling of file folders 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


• Box dimensions


• Color of box and printing ink


• Number of boxes required


• Purchase order number


• Number of boxes per shipping container


• Special delivery conditions