Case Study

Two-Story Container Lab, Breakroom & Control Room 

Portable & Resilient Observation Workspace 

A proppant company in West Texas needed a rugged, quickly deployable workspace to support sand mining operations for hydraulic fracturing (fracking) for oil and gas. The structure needed to combine visibility, climate control, and employee comfort, all in a relocatable format. Falcon Structures delivered a three-container modular solution tailored for industrial durability, extreme weather, and future mobility.

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Key Challenges

Designing for Durability, Safety, and Mobility 

  • Extreme environment: High winds, abrasive sand, and large temperature swings posed safety and longevity risks for traditional materials and design.
  • Remote location: The site’s isolation in rural west Texas made conventional construction impractical due to limited labor and high mobilization costs.
  • Visibility vs. durability: The customer required elevated visibility of mining operations, but standard glass would likely shatter from wind-driven debris.
  • Relocatability: The workspace had to be fully portable. No foundations, welding, or permanent fixtures left behind.

 

A Modular Workspace Built to Move and Endure 

Falcon engineered an observation workspace using three modified 20-foot shipping containers. The lower two containers were joined to create an open-span lab and breakroom, fully insulated and climate controlled. A third container was stacked above to serve as a control room with panoramic views of the mine.

To maintain portability, Falcon designed a self-supporting stair and platform system that connects directly to the containers, no ground anchoring required. For safe visibility, the standard glass windows were replaced with ½-inch clear polycarbonate panels glazed into custom frames. This ensured operators had a clear, shatter-resistant view of site activity even in high winds and blowing sand.

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The Solution

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Key Features Include

  • Shatter-resistant polycarbonate windows: Four large 72” x 36” panels in the control room withstand harsh wind and debris.
  • Portable, modular design: Entire structure, including stairs and platform, relocates easily without permanent site work.
  • Custom stair and platform system: Attached directly to containers for full structural integrity and OSHA compatibility.
  • Enhanced insulation: Dual-layer spray foam on all surfaces for temperature stability and dust protection.
  • Corten steel durability: Container-grade steel ensures long-term performance in arid, windy conditions.
  • Rapid offsite build: Completed in just 27 days of factory production.