ASTM D6804-02
(Guide)Standard Guide for Hand Hole Design in Corrugated Boxes
Standard Guide for Hand Hole Design in Corrugated Boxes
SCOPE
1.1 This standard provides guidelines for designing pre-cut apertures intended for use as hand holes in corrugated boxes during manual handling of boxed cargo.
1.2 Limitations—This standard offers guidance for package development and for subsequent testing of boxes to measure performance. It is not intended to provide specific information on the design of hand holes.
1.3 The values stated in inch-pound units are to be regarded as the standard. The SI units are for information only.
1.4 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 appropriate safety and health practices and determine the applicability of regulatory requirements prior to use.
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Designation: D 6804 – 02
Standard Guide for
Hand Hole Design in Corrugated Boxes
This standard is issued under the fixed designation D 6804; 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.
1. Scope 3.2 Definitions of Terms Specific to This Standard:
3.2.1 hand holes—apertures, pre-cut in corrugated boxes by
1.1 This standard provides guidelines for designing pre-cut
box manufacturers, as requested by box purchasers. These
apertures intended for use as hand holes in corrugated boxes
apertures facilitate manual handling during distribution and
during manual handling of boxed cargo.
improve grip during handling.
1.2 Limitations—This standard offers guidance for package
development and for subsequent testing of boxes to measure
4. Significance and Use
performance. It is not intended to provide specific information
4.1 It may be desirable at times to provide hand holes in
on the design of hand holes.
corrugated boxes. Package designers use hand holes to solve
1.3 The values stated in inch-pound units are to be regarded
ergonomic and handling problems associated with large or
as the standard. The SI units are for information only.
awkward containers. This guide provides an aid for proper
1.4 This standard does not purport to address all of the
hand hole design and use.
safety concerns, if any, associated with its use. It is the
4.2 Ergonomics:
responsibility of the user of this standard to establish appro-
4.2.1 In studying and applying ergonomic principles, of
priate safety and health practices and determine the applica-
primary concern is the need to provide a safe work environ-
bility of regulatory requirements prior to use.
ment for material handlers who may be required to lift or
2. Referenced Documents transport packages. A safe work environment is difficult to
define and varies with the package in question. Several
2.1 ASTM Standards:
ergonomic safety issues involve repetitive motions and spine
D 585 Practice for Sampling andAccepting a Single Lot of
loading in the lifting process. Other issues involve finger and
Paper, Paperboard, Fiberboard, and Related Product
foot protection.
D 996 Terminology of Packaging and Distribution Environ-
4.2.2 In distribution centers or warehouses, low back disor-
ments
ders have been identified as areas of elevated risk. Low back
D 1974 Practice for Methods of Closing, Sealing, and
problems continue to represent the most common and costly
Reinforcing Fiberboard Boxes
musculoskeletal disorders in the work place.
D 4332 Practice for Conditioning Containers, Packages, or
4.2.3 One method used to reduce the concern of distance of
Packaging Components for Testing
lift (spinal loading) is to bring the reach of the material
D 5276 Test Method for DropTest of Loaded Containers by
handler’s hands closer to the body. With large or awkward
Free Fall
boxes, placing hand holes in a more advantageous position can
E4 Practices for Force Verification of Testing Machines
solve this problem.
E 122 Practice for Calculating Sample Size to Estimate,
4.3 NIOSH:
With a Specified Tolerable Error, the Average for a
4.3.1 The National Institute for Occupational Safety and
Characteristic of a Lot or Process
Health (NIOSH) has published Work Practices Guide for
3. Terminology Manual Lifting. This document may be of assistance in
developingproperhandholesandtheirplacementforaspecific
3.1 Definitions—General definitions for packaging and dis-
package.
tribution environments are found in Terminology D 996.
4.4 Improper Use of Hand Holes:
4.4.1 Because of past lawsuits involving the use and misuse
of hand holes, the corrugated box industry prefers the term
ThisguideisunderthejurisdictionofASTMCommitteeD10onPackagingand
is the direct responsibility of Subcommittee D10.27 on Paper and Paperboard
Products.
Current edition approved June 10, 2002. Published August 2002. “EffectsofBoxFeaturesonSpineLoadingduringWarehouseOrderSelecting,”
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Marras, Granata, Davis,Allread, and Jorgensen, The Institute for Ergonomics, Ohio
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM State University.
Standards volume information, refer to the standard’s Document Summary page on NIOSH Technical Report No. 81-122 from the US Department of Health and
the ASTM website. Human Sevices.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
D6804–02
access hole instead of hand hole on specifications. This 5.1.2 Be a complex molded handle with a reinforcement
terminology may have to be agreed upon between supplier and mounted at the attaching point,
user.Fig. 1
5.1.3 Incorporate rope handles, and
4.4.2 Since all end use conditions and requirements cannot
5.1.4 Be reinforced by the box maker with reinforcing tape
be foreseen and since designing for worst case scenario for all
applied above them.
applications is prohibitively expensive, designers should fol-
5.2 If possible, position hand holes so that product and
low best practices. The prudent designer will consider product
internal cushioning material can add support for carrying (see
and package weight when deciding the proper use of a hand
Fig. 2). If the box must bear all the weight, it is best to position
hole.
the hand holes at least two (2) in. below the horizontal score
5. General Design Considerations
line of end panels to distribute the compressive forces and
avoid failure. When placing hand holes, consider product
5.1 Hand holes can take many forms (see Fig. 1). They can:
5.1.1 Be a simple hole in a box, balance and box closure method.
FIG. 1 Common Hand Hole Types
D6804–02
FIG. 2 Box with Internal Cushioning Material, showing location above Hand Hole to provide Added Support for Carrying
5.3 Some closure methods, such as taping, can affect hand
hole placement. When a hand hole is to be used with a box
style such as an RSC, which is to have a tape closure (see
Practice D 1974), it is best to allow enough room (2 to 2 ⁄2-in.)
for the end-leg of the tape (see Fig. 3). For a Bliss style box,
hand holes should be placed just below the top flange (see Fig.
4).
5.4 Several methods are used to reinforce a box above the
hand hole. For example, pressure sensitive, heat activated, and
adhesive based products can be used. Some have fiberglass or
polyester yarn reinforcement, some are tensilized, and some
are made of heavy kraft paper (see Fig. 5).
5.5 When possible, use curved type hand holes: they will
not tear as easily as the straight top design (see Fig. 4). The
curved design eliminates a sharp edge at the corners, resulting
in a more evenly distributed lifting force across the surface.
Note that a different type of grasping device will be required
whentestingcurvedhandholesasopposedtostraightones(see
X1.3, Apparatus).
6. Evaluation
6.1 The test methods in Appendix X1 are not ASTM
FIG. 3 RSC Style Box with Tape Closure, showing location of
standards, but are evaluation methods to assist in determining
Hand Hole 2.5 in. below top edge of box
the relative performance of hand holes during handling in the
distribution environment. The methods, in experimental trials,
7. Keywords
were shown to have high variability between laboratories;
however, within laboratories the methods were useful in 7.1 corrugated boxes; distribution environment; hand holes;
determining relative performance. manual handling
D6804–02
FIG. 4 Bliss Style Box showing Curved Hand Hole located just below the Top Flange
FIG. 5 RSC Style Box showing placement of Reinforcement Material around perimeter of box, just above Hand Hole
D6804–02
APPENDIX
(Nonmandatory Information)
X1. EVALUATION OF PERFORMANCE OF HAND HOLES IN CORRUGATED BOXES
X1.1 Summary of Methods X1.3.2 Method A, Jerk Test (see Fig. X1.2):
X1.3.2.1 Drop Test Apparatus, with a platform or other
X1.1.1 Method A, Jerk Test—Uses free-fall drop test appa-
feature which supports a corrugated box, such that the box may
ratus in conjunction with a support apparatus and grasping
be released for free-fall from a specified height. Support
device(s), imparting a sudden sharp arrested motion (jerk) to
apparatus for the grasping device must suspend the box at least
the hand hole area of a corrugated box. A grasping device
6 in. (150 mm) above the floor or test apparatus base. The
similar to that shown in Fig. X1.1 provides contact with the
support apparatus must secure the grasping device(s) so
hand hole.
essentially no yielding or elastic stretch occurs when the box
X1.1.1.1 This method is applicable for testing both one- and
falls and its motion is arrested by the device(s). A chain or
two-hand lifting of boxes. It is not intended for horizontal
flexible steel cable suspended from a rigid support or overhead
pulling of the box (see Method B, Tensile Test).
hoist may be used for this purpose.
X1.1.2 Method B, Tensile Test—Uses tensile testing ma-
X1.3.2.2 An elastic cord may be used to take up the slack in
chines having a constant free-running crosshead speed or
the chain or cable to make sure the grasping device(s) stays in
constant extension rate to determine the maximum load carry-
the hand hole(s). The cord shall be stiff enough to just support
ing abili
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