GEST 79 76 Edition 4

DESIGN AND CONSTRUCTION OF
FIXED TANKS AND TANK CONTAINERS

FOR THE TRANSPORT OF
LIQUID CHLORINE BY ROAD
GEST 79/76
4th Edition
January 2009
EURO CHLOR PUBLICATION
This document can be obtained from:
EURO CHLOR - Avenue E. Van Nieuwenhuyse 4, Box 2 - B-1160 BRUSSELS

E-mail: eurochlor@cefic.be Internet: http://www.eurochlor.org
GEST 79/76
4th Edition
Euro Chlor
Euro Chlor is the European federation which represents the producers of chlorine
and its primary derivatives.
Euro Chlor is working to:
 improve awareness and understanding of the contribution that chlorine

chemistry has made to the thousands of products, which have improved
our health, nutrition, standard of living and quality of life;
 maintain open and timely dialogue with regulators, politicians, scientists,

the media and other interested stakeholders in the debate on chlorine;
 ensure our industry contributes actively to any public, regulatory or

scientific debate and provides balanced and objective science-based
information to help answer questions about chlorine and its derivatives;
 promote the best safety, health and environmental practices in the

manufacture, handling and use of chlor-alkali products in order to assist
our members in achieving continuous improvements (Responsible Care).
***********
This document has been produced by the members of Euro Chlor and should not be reproduced in
whole or in part without the prior written consent of Euro Chlor.
It is intended to give only guidelines and recommendations. The information is provided in good
faith and was based on the best information available at the time of publication. The information is
to be relied upon at the user’s own risk. Euro Chlor and its members make no guarantee and
assume no liability whatsoever for the use and the interpretation of or the reliance on any of the
information provided.
This document was originally prepared in English by our technical experts. For our members’
convenience, it may have been translated into other EU languages by translators / Euro Chlor
members. Although every effort was made to ensure that the translations were accurate, Euro
Chlor shall not be liable for any losses of accuracy or information due to the translation process.
Prior to 1990, Euro Chlor’s technical activities took place under the name BITC (Bureau
International Technique du Chlore). References to BITC documents may be assumed to be to Euro
Chlor documents.
January 2009 Page 2 sur 26

GEST 79/76
4th Edition
RESPONSIBLE CARE IN ACTION
Chlorine is essential in the chemical industry and consequently there is a need for
chlorine to be produced, stored, transported and used. The chlorine industry has
co-operated over many years to ensure that its activities cause the minimum harm
to the well-being of its employees, local communities and the wider environment.
This document is one in a series which the European producers, acting through
Euro Chlor, have drawn up to promote continuous improvement in the general
standards of health, safety and the environment associated with chlorine
manufacture in the spirit of Responsible Care.
The voluntary recommendations, techniques and standards presented in these

documents are based on the experiences and best practices adopted by member
companies of Euro Chlor at their date of issue. They can be taken into account in
full or partly, whenever companies decide it individually, inthe operation of existing
processes and in the design of new installations. They are in no way intended as a
substitute for the relevant national or international regulations which should be fully
complied with.
It has been assumed in the preparation of these publications that the users will
ensure that the contents are relevant to the application selected and are correctly
applied by appropriately qualified and experienced people for whose guidance
they have been prepared. The contents are based on the most authoritative
information available at the time of writing and on good engineering, medical or
technical practice but it is essential to take account of appropriate subsequent
developments or legislation. As a result, the text may be modified in the future to
incorporate evolution of these and other factors.
This edition of the document has been drawn up by the Transport Working Group
to whom all suggestions concerning possible revision should be addressed
through the offices of Euro Chlor.

GEST 79/76
4th Edition
Summary of the Main Modifications in this version
Section Nature
Use of latest version of the ADR and inclusion of GEST 73/20
All
(eliminated)
2.1 Addition of letter “O” (oxidizer) in classification of chlorine
2.1 Creation of a subdivision 2 in the class 2 (chlorine class)
Updated definitions of the different types of pressure (see also 3.1.4
2.3
and 3.1.5) and of leak test definition
3.1.6 Removed all texts already present in the regulations referred to
3.1.7 Removed all texts already present in the regulations referred to
3.1.8 Precision on corrosion allowance
3.3.3 Small paragraph added to not recommend sumps
3.5.2 Precision added on surge plates, if present
3.5.3 Addition of UK technical solution with opening below the liquid level
Rewording on paragraph concerning valves and clarification added
3.5.4
on short dip pipe
3.5.5 Explanations added on protection of valves
3.5.6 Addition on rules for possible transport by ferryboat
3.5.7 Simplified the paragraph on thermal insulation (not recommended)
Addition of reference to the GEST 96/221 on tanker protection
3.5.8
systems
3.7 Addition of paragraph on support legs
4 Removal of information redundant with ADR requirements
4.4.2 Addition on paragraph on labelling empty tanks
5.1 Detailed information on the content of the test report was added
Removed details on impact strength tests and values already
5.2.1.4
present in ADR
5.2.2.5 Added subchapter on cleaning and drying
“Tank wagons” is replaced by “Shells and their equipment” for
5.3
periodic examination
5.4 Short paragraph added on maintenance
6.2 Filling procedures completed according to GEST 78/73

GEST 79/76
4th Edition
TABLE OF CONTENTS
1 GENERAL PRINCIPLES 7
2 DEFINITIONS 7
2.1 Chlorine Characteristics 7
2.1.1 Classification 7
2.1.2 Physical Properties 7
2.2 Tankers 8
2.3 Pressures 8
3 CONSTRUCTION OF TANKS 9
3.1 Rules for Design and Construction 9
3.1.1 Principle 9
3.1.2 Definition of Stresses 9
3.1.3 Reference Temperatures 9
3.1.4 Calculation Pressure 10
3.1.5 Test Pressure 10
3.1.6 Nominal Stress  (sigma) 10
3.1.7 Wall Thickness 10
3.1.8 Corrosion Allowance 10
3.1.9 Welding 10
3.2 Choice of Materials of Construction 11
3.3 Construction 11
3.3.1 The tank 11
3.3.2 Manhole 12
3.3.3 Pocket (Sumps) 12
3.3.4 Gas Tightness 12
3.3.5 Fittings 12
3.4 Heat Treatment 13
3.5 Fittings and Accessories 13
3.5.1 Gaskets 13
3.5.2 Partitions and Surge Plates 13
3.5.3 Openings 13
3.5.4 Valves 14
3.5.5 Protection of Equipment 15
3.5.6 Safety Relief Valves 15
3.5.7 Thermal Insulation 15
3.5.8 Protection against Damage 15

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4th Edition
3.5.9 Access Ladders and Platforms 16

3.6 External Protection 16
3.7 Support legs 16
4 MARKING 16
4.1 Colour coding 16
4.2 Labelling 16
4.2.1 Danger Label 17
4.2.2 Hazard and Substance Identification Plate 17
4.3 Marking 17
4.4 Particulars in the Consignment Document 18
4.4.1 Description of the Goods 18
4.4.2 Description of Empty Tanks 18
5 INSPECTION 18
5.1 Approval of Prototype 18
5.2 Acceptance Tests and Checks during Fabrication 19
5.2.1 On an Adequate Sample of Vessel 19
5.2.2 On all Vessels 19
5.3 Periodic Examinations 21
5.4 Maintenance 22
6 OPERATION 22
6.1 Preparation for Putting into Service 22
6.1.1 Preliminary Cleaning and Drying 22
6.1.2 Leak Testing 22
6.1.3 Check of Marking and Labelling 23
6.2 Filling and Emptying 23
6.3 Precautions 24
6.3.1 Against the Ingress of Moisture or Reactive Materials 24
6.3.2 During Dispatch of a Tank to Workshops 24
6.3.3 Decommissioning of a Tank 24
7 SAFETY MEASURES 24
7.1 In the Works 24
7.2 In Transit 24
8 REFERENCES 25

GEST 79/76
4th Edition
1 GENERAL PRINCIPLES
The transport of liquid chlorine under pressure in road tanks (ISO tank containers
or tank trucks) may take place only if it satisfies the conditions laid down in the
national and international regulations.
The present recommendation which deals with the design, testing, construction
and use of these road tanks is aimed at supplementing the statutory provisions of
national and international regulations (ADR, Directive 99/36 on transport able
pressure equipment …) with the experience gained in this field by the Euro Chlor
members.
There is a requirement defined in ADR for all companies involved with

transportation of chlorine to have a Dangerous Goods Safety Advisor who is
trained and examined in the application of ADR. This document supplements the
provisions of ADR specifically for chlorine road transport, and is intended to help
with implementation of the requirements, but does not in any way alter the
requirement for full compliance with ADR.
2 DEFINITIONS
2.1 Chlorine Characteristics
2.1.1 Classification
Chlorine is:
 a compressed gases, liquefied or dissolved, under pressure and/or low
temperature,
 completely gaseous at 20°C, under standard pressure of 101.3 kPA
 with a vapour pressure greater than 300kPA at 50°C
 and a critical temperature greater than 20°C
 T - toxic
 O - oxidising
 C - corrosive
It therefore has the classification "2, 2TOC "
Hazard code 265
The labelling 2.3, 5.1, 8 and 13
2.1.2 Physical Properties

 Critical temperature 144°C
 Boiling point at atmospheric pressure minus 34°C
 Density of the saturated liquid at 0°C 1,470 kg/m³

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4th Edition
 Density of the saturated liquid at 50°C 1,310 kg/m³

 Vapour pressure (see table below)
SI Units Units used by the ADR
Vapour pressure at 0°C 3.67 bars absolute 0.374 MPa absolute

See also GEST 91/168 - Physical, Thermodynamic and Selected Chemical

Properties of Chlorine.
2.2 Tankers
This document provides guidance for the design and operations associated with
road tankers (fixed and demountable tanks) and of ISO tank containers. Care
must be taken when referring to the relevant provisions in ADR which in some
instances differ in the legislation covering the two types of vehicle.
In the following requirements:

 "shell" means the tank itself (including the openings and their closures);
 "service equipment of the shell" means the filling, discharge, venting,
safety and heat-insulating equipment;
 "structural equipment" means the reinforcing, fastening protective and
stabilising members external to the shell;
 “empty tank” or “empty receptacle” means a tank which has been
emptied, but not cleaned and still contains a small residual amount of
product (unspecified quantity).
2.3 Pressures
In the International Transport Regulations, pressures of all kinds concerning
vessels are always given in MPa gauge pressure (relative pressure); on the other
hand, the vapour pressure of the product (chlorine) is always expressed in kPa
absolute pressure.
"Calculation pressure" means a notional pressure which is used to calculate the

thickness of the walls of the shell. In the case of chlorine, it is equal to the test
pressure.
"Maximum working pressure" means the highest of the following three pressures
 The highest effective pressure allowed in the shell during filling
(maximum filling pressure allowed)
 The highest effective pressure allowed in the shell during discharge
(maximum discharge pressure allowed)

GEST 79/76
4th Edition
 The effective pressure to which the shell is subjected by its contents

(including such extraneous gases as it may contain) at the maximum
working temperature.
"Test pressure" means the highest effective pressure applied during the pressure
test of the shell.
"Leak test" or "leakproofness test" means the test which consists in subjecting the
shell to an internal pressure between 25% and 100% of the maximum working
pressure.
A first leakage test should be made at low pressure (between 0.2 and 0.5 barg),
followed by the RID required leak test.
3 CONSTRUCTION OF TANKS
3.1 Rules for Design and Construction
3.1.1 Principle
The shells and their fastenings shall be capable of absorbing, under the maximum
permissible load, the following stresses:
 In the direction of travel; twice the total weight;
 At right angles to the direction of travel: the total weight;
 Vertically upwards: the total weight;
 Vertically downwards: twice the total weight.
3.1.2 Definition of Stresses

Shells, their attachments and their service and structural equipment shall be
designed to withstand:
 Static and dynamic stresses in normal carriage (see section 3.1.1);
 Prescribed minimum imposed stresses (see section 3.1.6).
In the case of vehicles in which the shell constitutes a stressed self-supporting
member, the shell shall be designed to withstand the stresses thus imposed in
addition to stresses from other sources.
3.1.3 Reference Temperatures

The reference temperatures are:
 Maximum temperature: +50°C.
 Minimum temperature: minus 40°C (Euro Chlor recommendation).
The value of minus 40°C accommodates venting and purging chlorine with dry
inert gas.
The construction of the tanks and their mode of affixing to the underframe shall be
such as to preclude with certainty any such reduction in the temperature of the

GEST 79/76
4th Edition
load-bearing components as would be likely to render them brittle. The fastenings

of the tanks shall themselves be so designed that even when the tank is at its
lowest working temperature, they still possess the necessary mechanical
properties.
3.1.4 Calculation Pressure

The ADR Tank Code for chlorine is P22DH. The minimum calculation pressure
which may be used is therefore 2.2MPa.
3.1.5 Test Pressure

Euro Chlor recommends to adopt a test pressure of 2.2 MPa for all tanks, and not
the lower values defined by ADR for tankers with diameter greater than 1.5 m.
3.1.6 Nominal Stress  (sigma)

At the calculation pressure, the stress  (sigma) at the most severely stressed
point of the shell shall not exceed the material-dependent limits. Allowance shall
be made for any weakening due to the welds. In addition, in choosing the material
and determining wall thickness, the maximum and minimum filling and working
temperatures should be taken into account
3.1.7 Wall Thickness

The determination of the thickness of the walls of the tank should be based on a
pressure which is equal, at least, to the calculation pressure, but account should
also be taken of the stresses relating to points 3.1.1 and 3.1.2 above (see ADR for
calculation formulas).
External reinforcing devices and corrosion allowance shall not be taken into
account in this calculation.
The ends of the tank should be of such a thickness that their strength is at least
equal to that of the shell. It is recommended that the thickness of the ends should
be not less than the thickness of the shell. See in additional sections 3.1.8 and 3.2.
Euro Chlor recommends a minimum shell thickness of 10 mm.
3.1.8 Corrosion Allowance

Dry liquid chlorine is not corrosive to steel. Euro Chlor recommends nevertheless
a minimum corrosion allowance of 1 mm. This corrosion allowance should be
added to the result for the wall thickness calculation.
3.1.9 Welding
Euro Chlor has chosen a value of 1 for the welding coefficient (lambda) in the wall
thickness calculation. It is advisable, in all cases, that all the weld beads should be
subjected to non-destructive testing, and as far as possible, visual checks should
be made on both faces of the welds.
A weld test-piece shall be taken from a weld. Particular attention should be paid to
junctions in welds. Non-destructive testing should be carried out to the extent of

GEST 79/76
4th Edition
100% by radiography (or by ultrasonics, magnetic or dye penetrant if radiography

is impossible) and should confirm that flaws are not present and that the execution
of the welding meets the stress requirements.
The ability of the manufacturer to carry out the welding work should be
acknowledged by the competent authority. The welding work should be carried out
by qualified welders, following a welding procedure, the quality of which (including
the necessary heat treatment) has been demonstrated by a trial of the procedure.
3.2 Choice of Materials of Construction

The material of which the shells and their fittings are constructed, and which are
likely to come into contact with chlorine, should not be attacked by it, nor should
they contain substances likely to react with it, to form dangerous compounds or to
weaken the material.
Since chlorine is frequently liquefied at low temperature and/or stored at low

pressure and low temperature, attention will be drawn to the necessity to take
these conditions into consideration for the materials of construction chosen, and all
the materials used shall be suitable for the minimum working temperature (minus
40°C).
The shells shall be constructed of carbon steel or of low alloy steel which is readily
weldable. See also GEST 79/82 - Materials of Construction for Use in Contact
with Chlorine.
Steels are used which are not subject to brittle failure at the minimum operating
temperature, for example unalloyed fine grain steels (killed steels). To ensure
good conditions for welding, as well as to provide a minimum thickness for
mechanical impact resistance, for example, Euro Chlor recommends that:
 the ultimate tensile strengths of the steel at rupture Rm should be
limited, to less than 570-600 N/mm².
 the steel should have a minimum elongation at fracture greater than
10000
Rm (recommendation ADR), but Euro Chlor recommends 11500 at
Rm
2
least, ie. 20% for Rm = 570N/mm .
The steels used for the construction of the shells and the weld beads shall, at their
minimum working temperature satisfy at least the following requirements with
regard to impact strength. The tests may be carried out with test-piece having
either U shaped notches or V or U shaped notches.
3.3 Construction
3.3.1 The tank

The tank shall consist essentially of:
 A straight cylindrical shell
 Two dished ends each formed from a single piece of material

GEST 79/76
4th Edition
 A manhole of maximum 500 mm diameter on the upper curved surface

(UIC 573 and EN 12561). The manhole should not cut through any line
of welding.
3.3.2 Manhole
There should be only one manhole with a maximum diameter of 500mm, located
on the upper cylindrical section of the barrel and not traversing any main seam
welds.
The manhole can take the form of either:

 a forged steel pad welded directly onto the tank
 a cylindrical branch fitted with a forged steel flange, the branch being as
short as possible.
In the first case, the flange should be fitted with studs for fixing the manhole; in the
second case, it is fixed with bolts.
It is pointed out that:

 The first solution has the advantage of reducing the risk of tearing-off in
the event of accident but has the disadvantage of the studs, corrosion of
which should be carefully monitored.
 The second solution increases the protuberance of the manhole but
removes the risk of corrosion of a fitting welded directly onto the tank.
 In both cases, the joint-flange assembly should be designed in such a
way that the jointing material cannot be expelled by operating or test
pressure from inside the tank.
3.3.3 Pocket (Sumps)

In some equipment, there can be a pocket in the bottom of the tank, under the
long dip-pipes to facilitate the complete emptying of the tank.
The pocket is a potential hazard if the chlorine contains a significant quantity of

nitrogen trichloride and is discharged in the gaseous phase, procedure absolutely
not recommened by Euro Chlor (the pocket would be the location where nitrogen
trichloride concentrates, see GEST 76/55 – Maximum Levels of Nitrogen
Trichloride in Liquid Chlorine).
3.3.4 Gas Tightness

The tanks intended for the transport of chlorine shall be closed and sealed in such
a way as to prevent any escape of gas. The liquid and gas-tightness of the items
of equipment shall be ensured even if the vehicle should overturn.
3.3.5 Fittings
The fittings and their supports should be fixed to the tank by welding. Screwing
directly into the tank is prohibited.

GEST 79/76
4th Edition
3.4 Heat Treatment

Stress relieving should be carried out, as required for the type of steel and welding
used, after the addition of all the welded fittings.
3.5 Fittings and Accessories
3.5.1 Gaskets
The gaskets shall be made of material compatible with chlorine and shall be
renewed as soon as their effectiveness is impaired, for example as a result of
ageing. The gaskets will be systematically replaced in case of opening.
They should preferably be of dense quality, and of proved suitability for chlorine.
(See GEST 94/216 - Experience of Non-Asbestos Gaskets on Liquid and Dry
Chlorine Gas Service).
A gramophone finish is recommended as required by the type of gasket used.

This should be applied to the surface of both the tank flange and the manhole.
3.5.2 Partitions and Surge Plates

If needed, surge plates and partitions in chlorine tanks should preferably be
perpendicular to the vessel shell rather than the conventional profiled design.
There are therefore no closed pockets resulting in the potential corrosion of the
pressure vessel wall. The plates must be suitably designed to provide adequate
strength and stiffness.
An opening at the bottom of the plates will allow liquid chlorine to drain from one
compartment to the next.
The area of any surge-plate shall be at least 70% of the cross-sectional area of the
tank in which the surge-plate is fitted.
3.5.3 Openings
Where legislation permits, shells intended for the carriage of chlorine may
incorporate openings below the surface level of the liquid in order to provide a
valve configuration with liquid and vent valves mounted at the front of the vessel in
a recessed chest (UK solution). However mounting of openings for any other
reason at a location in the tank where liquid chlorine would be normally in contact
with the joint should be avoided. Cleaning apertures (fist holes) at the bottom of
the shell shall not be used.
Where a tank or container has top-mounted connections, these should comply

with the UIC 573 standard. This limits the openings in the shell to one man-hole
closed by a manhole, and having three connection points for filling and emptying.
However two connection points (one liquid and one gas) is acceptable. Some
tanks have a manhole in the middle of one end, suitably protected it conforms to
national regulations. The number of openings in the shell shall always be kept to a
minimum.

GEST 79/76
4th Edition
3.5.4 Valves
Filling and discharge orifices shall be equipped with external valves, fixed to the
valve plate, having a secondary internal security closing valve, situated below the
valve plate and closing instantaneously when not held open by the external valve.
The valves shall be operated remotely, with a possibility of rapid remote closure in
case of emergency, including the automatic closure in the event of unintended
movement of the tank while filling or emptying.
The external valve shall be capable of being closed by a blank flange.

Consideration must be given to the way this final closure (blank flange) will be
removed and how the operator will be able to verify that excessive gas is not
present behind it upon first breaking the joint and before it is completely removed.
The position and/or direction of closure of the valves should be clear and
unambiguous.
These valves (the main valve and the internal check valve) should be of a type in
line with Euro Chlor specifications (refer to GEST 75/46 - Pneumatically
Operated Valves for Use on Rail and Road Tankers and ISO-Containers for
Liquid Chlorine).
However, irrespective of the type of valve, its method of attachment should be very
strong and of such a nature that its condition can be easily checked before each
refilling operation.
In case of necessity, the valves can be operated manually with a special tool. To
avoid any misuse, this tool will not be available on the railcar but will be part of the
emergency kits of the intervention teams,
The one or two valves intended for the discharge of liquid chlorine are fitted with
dip-pipes which extend into the lowest part of the tank.
The gas phase valve may be fitted with a short dip-pipe, to detect overfilling. The
installation of such a dip-pipe has some advantages and disadvantages.
 Disadvantages:
 accumulation of inert gas beneath the manhole.
 chlorine flashback
 possibility of a slug of liquid being transferred to, and damaging, the
transfer compressor at the end of a filling operation, for factories which
use this type of equipment.
 Advantages:
 Warning that the tank is overfilled.
In any case, it is desirable, even in the absence of short dip-pipes, that the internal
safety valve should be as short as possible.
The loading installation should also respect the following conditions:

 knock-out drum installed in the off-gas system

GEST 79/76
4th Edition
 liquid chlorine detection systems in the knock-out drum or in the off-gas

system
 enough off-gas absorption/recovery capacity
3.5.5 Protection of Equipment

The items of equipment, wherever situated, shall be protected against the risk of
being wrenched off or damaged during carriage or handling. They shall possess a
degree of safety comparable to that of the shell itself.
The manhole and valves shall be protected by an external cover which shall be
designed strong enough to protect against external impact.
For top mounted fittings, the protection shall be provided for example by means of
a skirt fixed on the manhole flange where an by a steel dome of heavy thickness
attached to the skirt and fitted with heavy duty hinges and closure securing against
any accidental or unauthorised opening. Particular attention must be given to
ensure that there is no water traps, with the cover in the open or closed position; it
must be designed to allow for the drainage of water from it.
In the case of recessed chest mounted valves, the cover should take the form of
one or two protective doors, while for top mounted valves it must be designed in
the form of a dome cover. Particular attention must be given to ensure that there
are no water traps, with the covers in the open or closed positions.
3.5.6 Safety Relief Valves

The ADR envisages the possibility of fitting chlorine road tankers with two safety
relief valves preceded by a bursting disc. This equipment is not recommended by
Euro Chlor (see GEST 80/92 - Installation of Relief Valves on Road and Rail
Tankers and ISO-Containers for the Transport of Liquid Chlorine).
Where tankers or ISO containers are transported by ferry, local regulations may
follow the road requirements (by agreement) rather than the International Maritime
Organisation (IMO) requiring relief valves, and in these circumstances, no relief
valve is fitted.
3.5.7 Thermal Insulation

Chlorine road tankers do not normally carry thermal insulation in Europe.
A complete cladding of insulating materials is not recommended because:

 It makes it difficult to inspect the outside wall of the tank
 water can seep into the insulating material with possible corrosion of the
shell (accelerated by temperature cycling due to operations).
3.5.8 Protection against Damage

The shell may be provided on both sides, at a height situated between its
centreline and its lower half, with protection against side and rear impact,
consisting of rolled metal crash barriers. These should be designed in accordance
with the GEST 96/221 – Protection of Road Tankers for the Bulk Transport of
Chlorine. Protection in the event of overturning, which can take the form of

GEST 79/76
4th Edition
strengthening rings, protective canopies, or transverse or longitudinal members,

must be so shaped that in the event of overturning no damage is caused to the
fittings and accessories mounted on the upper part of the shell. No additional risk
to the shell must be created by these additional protections.
It is recommended for chlorine tank vehicles (tankers or semi-trailers) that the

filling and emptying components be specially protected, for example by:
 Substantial roll-over bars
 A very thick specially shaped cover dome fitted with very strong hinges
and fastenings
 A skirt encircling the manhole and extending the contour of the
protective cover (see section 3.5.5)
 An enclosed valve chest which houses the liquid and gas valves
3.5.9 Access Ladders and Platforms

These accessories should be removable and not fixed directly onto the tank but to
brackets welded onto the tank. All platforms must have handrails and of sufficient
width to ensure the safety of personnel working on the tank.
3.6 External Protection

External protection of the tank should be carried out by means of paint having the
highest possible resistance to chlorine and should be applied after shot-blasting.
The finishing coat should be with a reflecting character.
3.7 Support legs

The trailer unit of the vehicle shall be fitted with two support legs which, if filling or
discharging without the tractor unit connected, must be adequately supporting the
trailer before the operation commences. These legs will be secured to guarantee
the stability of the tanker; for safety reason, an additional support system should
also be provided.
4 MARKING
4.1 Colour coding

Shells intended for the carriage of chlorine must be marked by an unbroken
orange-coloured band, about 30 cm wide, encircling the shell at mid-height.
4.2 Labelling
This is two-fold and comprises:

GEST 79/76
4th Edition
4.2.1 Danger Label
N° 2: toxic N° 5.1: oxidising N° 8: corrosive
4.2.2 Hazard and Substance Identification Plate

Tank cars carrying chlorine shall be fitted, on each side, with a non-reflecting
rectangular orange-coloured plate with a black border.
Each plate shall carry identification numbers as follows:

hazard: 265
substance: 1017
4.3 Marking
Every shell shall be fitted with a corrosion-resistant metal plate permanently
attached to the shell in a place readily accessible for inspection. The following
particulars at least shall be marked on the plate by stamping or by any other
similar method. These particulars may be engraved directly on the walls of the
shell itself, if the walls are so reinforced that the strength of the shell is not
impaired (this last solution is not recommended).
 Approval number
 Manufacturer’s name or mark
 Manufacturer’s serial number
 Year of manufacture
 Test pressure in MPa (gauge pressure)
 Capacity in litres
 Design temperature (minus 40°C)
 Date (month and year) of initial test and most recent periodic test
 Stamp of the expert who carried out the tests
 Material of the shell.
In addition, the maximum working pressure allowed shall be indicated.
The following particulars shall be inscribed on the tank-vehicle itself or on a plate:

 Name of operator
 Unloaded weight (tare)
 Permissible maximum weight.

GEST 79/76
4th Edition
The following additional particulars shall be marked by stamping or by any other

similar method on the plate prescribed:
 The name of the gas in full: CHLORINE
 The maximum load in kg
 Allowable filling temperature: minus 35°C.
On shells equipped with thermal insulation: inscription “thermally insulated”.
4.4 Particulars in the Consignment Document
4.4.1 Description of the Goods

The Description of the Goods in the Consignment note shall be:
UN 1017, CHLORINE, 2 3, (5.1, 8)
4.4.2 Description of Empty Tanks

The Description of empty tanks, in the Consignment Document must be indicated
in all languages of the countries concerned by the transport and precise:
Empty tank returned, uncleaned, 2.
5 INSPECTION
5.1 Approval of Prototype

The competent authority or its authorised body shall issue a design approval
certificate for a new design of a tank. This certificate shall attest that a tank road
car has been surveyed by that authority, is suitable for its intended purpose and
meets the requirements of ADR. When a series of tanks are manufactured without
change in the design, the certificate shall be valid for the entire series. The
certificate shall refer to the prototype test report, the substances or group of
substances allowed to be carried, the material of construction of the shell and an
approval number. The approval number shall consist of the distinguishing sign or
mark of the country in whose territory the approval was granted, i.e. the
distinguishing sign for use in international traffic as prescribed by the convention
on road traffic, and a registration number. Any alternative arrangements according
to ADR requirements shall be indicated on the certificate.
The prototype test report for the design approval shall include at least the
following:
 The results of the applicable framework test specified in ISO 1496-
3:1995
 The results of the initial inspection and test according to ADR
 The results of the impact test when applicable.

GEST 79/76
4th Edition
5.2 Acceptance Tests and Checks during Fabrication

Tanks and their equipment shall, either together or separately, undergo an initial
inspection before being put into service. This inspection shall include a check that
the tank conforms to the approved prototypes, a check of the design
characteristics, an external and internal examination, a hydraulic pressure test at
the test pressure indicated on the data plate, and a check of satisfactory operation
of the equipment.
If the shells and their equipment are tested separately, they shall be jointly
subjected to a leakproofness test after assembly.
5.2.1 On an Adequate Sample of Vessel

The following tests shall be carried out:
5.2.1.1 Tests on the Material

The test on the material of construction shall include at least, yield stress, tensile
strength, permanent elongation after rupture: the values obtained for these tests
shall comply with the respective EN regulations.
5.2.1.2 Thickness
Measurement of the thickness of the thinnest part of the wall.
5.2.1.3 Homogeneity
Checking the homogeneity of the material for each manufacturing batch.
5.2.1.4 Impact strength

For this property, the material of construction for receptacles intended for the
carriage of chlorine should be tested according to the methods described in ADR.
5.2.2 On all Vessels
5.2.2.1 100% radiographic examination

, Examination of all welds before stress-relieving is carried out (see section 3.1.9).
5.2.2.2 Physical examination of the inside and outside of the tanks.
5.2.2.3 Pressure Test

As recommended in section.3.1.5, a hydraulic test shall be carried out in all cases
at a minimum pressure of 2.2 MPa.
The vessel shall withstand the test pressure without undergoing permanent
deformation or exhibiting cracks.

GEST 79/76
4th Edition
5.2.2.4 Determination of Capacity

The capacity of each shell intended for the carriage of chlorine shall be
determined, under the supervision of an expert approved by the competent
authority, by weighing or volumetric measurement of the quantity of water which
fills the shell at 15°C, any error in the measurement of shell capacity shall be of
less than one per cent.
The maximum filling weights allowed shall be prescribed by an approved expert.
The filling ratio used shall comply with the applicable national or international
legislation. The filling ratio acceptable for chlorine within Europe is 1250 kg/m³.
5.2.2.5 Cleaning and Drying

The following checks must be done:
 no areas of rust or scale
 no traces of moisture
 no traces of grease
 no extraneous material
Before the manhole is assembled, it shall be confirmed that there are no traces of
water on the walls, inside the valve work and in the joints. The tank and its
accessories should be carefully degreased, cleaned and dried. Drying shall be
carried out with oil free dry air and continued until a dew point below minus 40°C is
obtained in the drying gas leaving the manhole.
5.2.2.6 Assembly Procedures

There shall be an auditable, written procedure to ensure that:
 Correct gaskets are used
 Correct greases are used
 Correct bolts and nuts (see GEST 88/134 Stud Bolts, Hexagon Bolts
and Nuts for Liquid Chlorine)
 Valves and equipment do not contain any moisture
For greasing internal equipment or items which are likely to come into contact with
liquid chlorine, only a grease compatible with chlorine shall be used
(chlorofluorinated grease). Standard common greases are not compatible with
chlorine.
5.2.2.7 Leakproofness Testing

After drying the shell and fitting the items of equipment, the complete assembly
shall be subjected to a leak test according to a method agreed by the inspection
body.
The leak test for shells intended for the transport of chlorine shall be carried out at
a pressure of at least 0.4 MPa (gauge pressure).

GEST 79/76
4th Edition
If the shells and their equipment are tested separately, they shall be jointly
subjected to a leakproofness test after assembly.
5.2.2.8 Examination of Markings and Labelling

See section 4.
5.2.2.9 Determine a tare weight
5.3 Periodic Examinations

Shells and their equipment shall undergo an external inspection at each
loading/off-loading operation, including a tare weighing and examination of the
equipment and the markings. Tanks shall also undergo periodic inspections at
fixed intervals.
The periodic inspections shall include an external and internal examination and a
hydraulic pressure test. Valves must be removed during the periodic examinations,
to eliminate contamination potential from moisture. The hydraulic test is made with
blank flanges at the valves openings.
A tare weight check shall then be carried out and an examination of the equipment
and the markings.
The thickness of the tank wall shall, during the whole of its working life, be equal to
or greater than the minimum defined value (see section 3.1.7).
Any loss of wall thickness must be inspected by the approved inspection body.
This inspection must ascertain the root cause of the material loss and determine
whether the mechanism would continue and cause unacceptable degradation
before the next periodic inspection. The tank may then be repaired as long as the
overall integrity of the tank is not affected.
Periodic tests shall take place according to the requirements defined in ADR.
The tests, inspections and checks in accordance with ADR shall be carried out by
the expert approved by the competent authority. Certificates shall be issued
showing the results of these operations.
When the safety of the shell or of its equipment may be impaired as a result of
repairs, alterations of accident, an exceptional check shall be carried out by the
competent authority or by the expert approved by that authority.
The leak test of the fully equipped tank shall be carried out at 0,4 MPa (see
section5.2.2.7).
Renewal of gaskets after hydraulic testing is obligatory.
Following this test, the tank will be cleaned and dried (see 5.2.2.5)

GEST 79/76
4th Edition
5.4 Maintenance
It is essential to minimise the potential deterioration of the materials of the vessel
caused by the opening the vessel for maintenance. Therefore if at all possible,
maintenance should be carried out at the same time as the periodic inspection.
More detailed guidance is provided in the following documents:
GEST 79/78 – Code of Good Practice for the Operations to be Carried Out
Before and after Maintenance on Rail and Road tankers and ISO Containers
of Liquid Chlorine
GEST 76/53 – Code of Good Practice for Installation, Removal and

maintenance of Pneumatic Valves on Rail and Road Tankers and ISO
Containers for Liquid Chlorine
6 OPERATION
The tankers used for chlorine transportation will be dedicated, and no other
product will be allowed.
6.1 Preparation for Putting into Service
6.1.1 Preliminary Cleaning and Drying

The inspection prior to putting into service must include checks before drying
5.2.2.5.
The container and its accessories shall carefully be degreased, cleaned and dried
with oil free dry air. Drying shall be continued until a dew point below minus 40°C
is obtained in the drying gas leaving the two available valves, after allowing a
sufficient length of time for the homogenisation of the gaseous mixture inside the
tank. A dryness check shall be carried out as a routine on an empty tank after
testing or cleaning, before introducing chlorine. For greasing internal equipment or
items which are likely to come into contact with liquid chlorine, only a grease
compatible with chlorine shall be used (chlorofluorinated grease).
To prevent ingress of moisture after drying, the barrel shall be maintained at a

pressure of 0.2 barg with dry gas.
6.1.2 Leak Testing

Before putting into service, all the valves and accessories shall be tested in such a
way as to ensure their complete gas-tightness under the conditions of use after
drying:
The test methods may be Air pressure greater than 0. 4 MPa, but less than the
operating pressure, leaks being tested for by means or soapy water
Final test with a mixture of chlorine/dry gas at 0.2 MPa, introduced by means of a
dip-pipe valve, the gasket being checked with ammonia after the test pressure has
been retained for at least 1 hour.

GEST 79/76
4th Edition
In order to check the gas-tightness of the plate covering the manhole, the skirt, if
fitted, may be temporarily removed.
6.1.3 Check of Marking and Labelling
6.2 Filling and Emptying

All the instructions of the GEST 78/73 - Design Principles and Operational
Procedures for Loading/Off Loading Liquid Chlorine Road and Rail Tankers
and ISO-Containers should be adhered to; the Cefic-ECTA - Behaviour based
Safety – Guideline for the safe loading and unloading of road freight vehicles
gives additional guidance.
The internal pressure and the wall temperature of the vessel before filling can give
an idea of possible presence of nitrogen; in this case the vessel should be
degassed before filling.
Before being filled for the first time after maintenance or inspection the tank should
be purged with chlorine gas to remove air. If liquid is detected in the vent line
during the first filling, it is an indication that the internal dip pipe is incorrectly fitted
to the gas connection.
Care must be taken to prevent the ingress of moisture during filling.
The vessels shall be charged to a maximum fill ratio of 1.25 (1250 kg of liquid
chlorine per m³ of capacity of the vessel) keeping a gas phase in case the
temperature reaches 50°C; the residual chlorine quantity existing in the tank prior
to loading will be discounted to avoid overfilling.
After filling, degassing of the remaining inert gasses shall be performed to avoid
an increase of the tank pressure above the acceptable limit when the temperature
of the chlorine will rise during transport.
ADR specifies that, where shells intended for the carriage of liquids have a
capacity greater than 7,500 litres and are not fitted with surge plates, they shall be
filled with more than 80% of their capacity or less than 20%.
The leakproofness of the shell closures shall be verified by the sender after the
shell has been filled. Where several closure systems are fitted in series, the
nearest to the substance being carried shall be closed first.
Discharge from road tankers should always be liquid chlorine. Where gaseous
chlorine is required in a process, the chlorine shall be taken from the road barrel
as liquid and vaporised in a separate vaporiser. Where removal of gaseous
chlorine from a road barrel is unavoidable because of exceptional circumstances,
special precautions shall be taken to prevent the risk of a nitrogen trichloride
explosion. For further guidance, see GEST 76/55 – Maximum Levels of
Nitrogen Trichloride in Liquid Chlorine.
To be accepted for carriage, empty shells must be closed in the same manner and
leakproof in the same degree as though they were full.

GEST 79/76
4th Edition
6.3 Precautions
6.3.1 Against the Ingress of Moisture or Reactive Materials

Adequate precautions should be taken to avoid all entry of moisture, of reactive
materials, or of hydrogen into the tank. In the same way, if an inert gas is used for
transfer or purging, this gas should have a dew point of less than minus 40°C at
atmospheric pressure. The pressure of this gas shall be at least 1.5 to 2 bars
greater than that likely to exist in the tank, and all necessary measures shall be
taken to ensure that this difference is maintained permanently, and that the gas is
not contaminated by other fluids.
6.3.2 During Dispatch of a Tank to Workshops

Any chlorine tank sent for attention in an external non-specialist workshop should
first be emptied, vented, and neutralised (usually by filling and washing with
water), operations confirmed by a certificate and a label apposed on the tank.
6.3.3 Decommissioning of a Tank

Decommissioning of a tank can take place only with the agreement of an approved
expert. In this case, the tank should be emptied, vented, and neutralised (sodium
carbonate for example) and unlabelled; a certificate will formalise these
operations.
7 SAFETY MEASURES
As chlorine is a high risk dangerous good, particular precautions must be taken

during work, transit, etc…
7.1 In the Works

Chlorine tank vehicles should be parked well away from risk of collision and of
fire/explosion, and in a monitored parking, even if the tank is empty (but not
cleaned).
Filling and emptying of tank wagons should be carried out in special bays reserved
for this purpose and constructed according to GEST 78/73 - Design Principles
and Operational Procedures for Loading/Off Loading Liquid Chlorine Road
and Rail Tankers and ISO-Containers.
7.2 In Transit
Transport of chlorine by tank vehicle may be the subject of special measures
prescribed by national or international regulations.
The parked tank vehicle should always remain under surveillance.
There should exist an emergency intervention plan for action in the event of
accident or incident. It provides for the immediate call-out of the nearest team of
chlorine specialists.

GEST 79/76
4th Edition
8 REFERENCES
 GEST 75/46 - Pneumatically Operated Valves for Use on Rail and Road
Tankers and ISO-Containers for Liquid Chlorine
 GEST 76/53 – Code of Good Practice for Installation, Removal and

maintenance of Pneumatic Valves on Rail and Road Tankers and ISO
Containers for Liquid Chlorine
 GEST 76/55 – Maximum Levels of Nitrogen Trichloride in Liquid

Chlorine
 GEST 78/73 - Design Principles and Operational Procedures for

Loading/Off Loading Liquid Chlorine Road and Rail Tankers and ISO-
Containers
 GEST 79/78 – Code of Good Practice for the Operations to be Carried

Out Before and after Maintenance on Rail and Road tankers and ISO
Containers of Liquid Chlorine
 GEST 79/82 - Materials of Construction for Use in Contact with

Chlorine
 GEST 80/92 - Installation of Relief Valves on Road and Rail Tankers

and ISO-Containers for the Transport of Liquid Chlorine
 GEST 88/134 - Stud Bolts, Hexagon Bolts and Nuts for Liquid Chlorine
 GEST 91/168 - Physical, Thermodynamic and Selected Chemical

Properties of Chlorine
 GEST 94/216 - Experience of Non-Asbestos Gaskets on Liquid and Dry

Chlorine Gas Service
 GEST 96/221 – Protection of Road Tankers for the Bulk Transport of

Chlorine
 Cefic-ECTA - Behaviour based Safety – Guideline for the safe loading

and unloading of road freight vehicles

GEST 79/76
4th Edition
Industrial consumers of chlorine, engineering and equipment supply companies

worldwide and chlorine producers outside Europe may establish a permanent
relationship with Euro Chlor by becoming Associate Members or Technical
Correspondents.
Details of membership categories and fees are available from:
Euro Chlor
Avenue E Van Nieuwenhuyse 4
Box 2
B-1160 Brussels
Belgium
Tel: +32 2 676 7211
Fax: +32 2 676 7241
e-mail: eurochlor@cefic.be
Internet: http://www.eurochlor.org

GEST 79 76 Edition 4

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DESIGN AND CONSTRUCTION OF

FIXED TANKS AND TANK CONTAINERS

EURO CHLOR PUBLICATION

This document can be obtained from:

EURO CHLOR - Avenue E. Van Nieuwenhuyse 4, Box 2 - B-1160 BRUSSELS

Euro Chlor is working to:

 improve awareness and understanding of the contribution that chlorine

 maintain open and timely dialogue with regulators, politicians, scientists,

 ensure our industry contributes actively to any public, regulatory or

 promote the best safety, health and environmental practices in the

January 2009 Page 2 sur 26

RESPONSIBLE CARE IN ACTION

The voluntary recommendations, techniques and standards presented in these

January 2009 Page 3 sur 26

Summary of the Main Modifications in this version

January 2009 Page 4 sur 26

January 2009 Page 5 sur 26

3.5.9 Access Ladders and Platforms 16

January 2009 Page 6 sur 26

There is a requirement defined in ADR for all companies involved with

2.1 Chlorine Characteristics

Hazard code 265

The labelling 2.3, 5.1, 8 and 13

2.1.2 Physical Properties

January 2009 Page 7 sur 26

 Density of the saturated liquid at 50°C 1,310 kg/m³

Vapour pressure at 0°C 3.67 bars absolute 0.374 MPa absolute

See also GEST 91/168 - Physical, Thermodynamic and Selected Chemical

In the following requirements:

"Calculation pressure" means a notional pressure which is used to calculate the

January 2009 Page 8 sur 26

 The effective pressure to which the shell is subjected by its contents

3.1 Rules for Design and Construction

3.1.2 Definition of Stresses

3.1.3 Reference Temperatures

January 2009 Page 9 sur 26

load-bearing components as would be likely to render them brittle. The fastenings

3.1.4 Calculation Pressure

3.1.5 Test Pressure

3.1.6 Nominal Stress  (sigma)

3.1.7 Wall Thickness

Euro Chlor recommends a minimum shell thickness of 10 mm.

3.1.8 Corrosion Allowance

January 2009 Page 10 sur 26

100% by radiography (or by ultrasonics, magnetic or dye penetrant if radiography

3.2 Choice of Materials of Construction

Since chlorine is frequently liquefied at low temperature and/or stored at low

3.3.1 The tank

January 2009 Page 11 sur 26

 A manhole of maximum 500 mm diameter on the upper curved surface

The manhole can take the form of either:

It is pointed out that:

3.3.3 Pocket (Sumps)

The pocket is a potential hazard if the chlorine contains a significant quantity of

3.3.4 Gas Tightness

January 2009 Page 12 sur 26

3.4 Heat Treatment

3.5 Fittings and Accessories

A gramophone finish is recommended as required by the type of gasket used.

3.5.2 Partitions and Surge Plates

Where a tank or container has top-mounted connections, these should comply

January 2009 Page 13 sur 26

The external valve shall be capable of being closed by a blank flange.

The loading installation should also respect the following conditions: