To understand the requirements imposed by the US Department of Transportation on the Drip Torch.
Why are there requirements?
The Drip Torch is a fuel container (packing group II) that can be transported on open roadways. As such, we need to ensure that the product conforms to federal laws and is safe for transportation in real-world applications.
What are the requirements?
The following requirements have been identified as being related to the production of a Drip Torch. Requirements listed in red require your action throughout the production process.
The Drip Torch tank must be constructed of aluminum at least 99% pure or of an aluminum base alloy (49 CFR § 178.511). The material used must be of a type and of adequate thickness in relation to the capacity of the tank and its intended use.
- The tank consists of 6063-T6 (tube) and 356-T6 (castings) aluminum alloys.
- Ensure that material certifications are documented when receiving materials.
The seams of the Drip Torch tank must be mechanically seamed or welded (49 CFR § 178.511).
- The seams of the Drip Torch tank (along the top and bottom castings) are TIG welded.
Drip Torches must be powder coated red (RAL 3001) (29 CFR § 1910.144).
- Drip Torches that pass initial leakproofness testing are sent to be powder coated by a third-party supplier.
The Drip Torch tank’s opening must not exceed three inches in diameter and designed so that it can remain secure and leakproof under normal conditions of transport (49 CFR § 178.511). Openings must have a gasket or other sealing element unless inherently leakproof.
- The Tank Top is designed to be machined with a 2.5" main opening, a recess for a gasket, and about a 1/4" opening for the Breather Valve, which is sealed with an o-ring.
- Install a Tank Cover Gasket and sealed Breather Valve before final leakproofness testing.
Drop, leakproofness, hydrostatic pressure, and stacking tests must be done at least once every 12 months using random samples (49 CFR § 178.601). Retain packaging test reports for the duration of manufacture and two years thereafter, design test reports for six years after testing, and periodic retesting for one year after testing.
- Annual performance testing is conducted by the Quality Management Team or third-party suppliers.
Every drip torch tank must be completely submerged under water with not less than 3 psi of compressed air (49 CFR § 178.604). The tank passes the leakproofness test if there is no leakage of air from the packaging.
- Production leakproofness testing is conducted at least once according to the approved testing procedure.
The Drip Torch tank bottom must be permanently marked with the following symbols (49 CFR § 178.503):
- UN symbol
- “3B1” - aluminum jerrican with a non-removable head
- “Y” - meets Packing Group II performance tests
- “100” - hydrostatic pressure tested to 100-109 kPa during annual testing (actual testing is 15 psi, or 103.4 kPa).
- The last two digits of the year of manufacture
- We stamp the two-digit month and year of manufacture in the production process after powder coating.
- “USA” - country of manufacture and marking
- The company's name, address, and “M-5609”, which is our company code registered with the Associate Administrator for Hazardous Materials Safety.
Every Drip Torch tank must be labeled with a durable and weather resistant “Flammable Liquid” sticker in accordance with DOT standards (49 CFR §§ 172.407,419).
- Flammable Liquid stickers that conform to DOT standards (purchased material) are adhered to the Drip Torch tank before final packaging.