Are you designing a shipping container structure? As you start to think about a design, you may realize you have a lot of unanswered questions about shipping container modifications. We created this guide to answer frequently asked questions about container modifications to help you design a structure that meets your business needs – read on to learn more.
Here at Falcon, when we add doors and windows to shipping containers, we frame the openings with steel tubing. Similarly, we often create custom openings, called utility ports – shaped, rectangular sheets of metal – or pass throughs – appropriately sized steel pipes – to install equipment. Both utility ports and pass throughs allow wires to easily exit the container without the need to cut into the corrugated steel once the container arrives on site.
The ideal type of window depends entirely on the intended purpose of the structure. Don’t assume that all windows are interchangeable. Aside from the variety in sizes, many types of windows come with features that may not be necessary for every application. Consider which window options are available before designing a shipping container structure. Keep in mind that any window larger than 3-feet by 3-feet will likely need structural reinforcement.
Our production team here at Falcon Structures utilizes internal systems to standardize each cut and framed opening. These window frames are made to fit windows of varying sizes and allow for quick installation of the desired window.
Cargo doors use steel bars and a cam and lock system to fasten the doors shut. This is often the tricky part since it may take some finessing to properly align the lock. Always start with the right-hand cargo door and pull both handles at the same time. Check out this how-to video for a step by step walk-through.
Shipping container cargo doors are heavy-duty, weather-tight, and secure. Companies across the world trust containers to ship valuable goods over turbulent seas. As containers are repurposed into modified structures, cargo doors often receive security-enhancing modifications, such as additional locks, that allow the doors to remain operable.
If you begin having trouble opening the cargo doors of your shipping container, or if you have a “used container” – those that have taken multiple trips overseas – you should consider lubricating the cargo doors. After cleaning the cam, keeper, and door hinges, apply lubricant to these areas. We recommend you start with the right door as it is the first to open. Door hinge corrosion from sea travel can make doors difficult to open, but one trip containers aren’t likely to face this problem.
Shipping container doors can include several types of locks and handles to increase security. The options for a personnel door include a keypad entry doorknob and latch guard or latch protector. A latch protector is a flat piece of metal bolted over the locks, decreasing the likelihood of forced entry.
Cargo doors are often modified to include lock boxes to deter thieves. Here at Falcon, we can customize a lock box and weld it to the cargo door to protect the lock from bolt cutters and other theft devices. These boxes include lock tabs that are welded inside the box to increase security and reduce vulnerability.
Many types of doors are installed in shipping containers. Roll-up doors, sometimes called overhead doors, lift from the bottom and roll up inside the container. They are lockable, easily unlatched, and lightweight. These doors are also welded into the container wall and can be installed almost anywhere along the side walls or at the ends of the container. Keep in mind that there are various grades of roll-up doors, and depending on the frequency of use, it may be worth an additional cost to purchase a premium roll up door. Some lower-level roll-up doors aren’t designed for frequent use and can quickly wear out.
Side doors are cargo doors at the end of a shipping container. Cargo Doors are heavy-duty, weather-tight, and secure swinging doors. They use a cam and lock system which ensures that the contents inside the container are protected against theft and environmental threats.
Because manufacturers build shipping containers out of steel, they can easily get hot inside. Depending on the external temperature and direct sunlight, an unmodified shipping container will get very hot under direct sunlight. Although, as manufacturers modify shipping containers into repurposed structures, the internal temperature becomes easier to manage thanks to added insulation and air conditioning units. For example, many companies confidently store valuable equipment that’s prone to overheating in modified shipping container equipment shelters, making modified containers easy to regulate.
The amount of insulation your structure requires depends on the climate of your job site and the function of the modified container. You’ll need insulation if you plan on living, working, or storing temperature-sensitive assets in the container. Our three most popular insulation options include: Styrofoam, rolled batt, and spray foam.
Styrofoam insulation is ideal for storage containers because it doesn’t require interior framing, but it still helps regulate internal temperature. Batt insulation, which is common in attics and crawl spaces, works well for container offices and living spaces. And finally, spray foam offers a functional climate-controlled space for temperature sensitive equipment storage. Take special care when designing with spray foam as it is flammable. It should be protected from direct heat sources.
The amount of insulation your structure requires depends on the climate of your job site and the function of the modified container. You’ll need insulation if you plan on living, working, or storing temperature-sensitive assets in the container. Our three most popular insulation options include: Styrofoam, rolled batt, and spray foam.
Styrofoam insulation is ideal for storage containers because it doesn’t require interior framing, but it still helps regulate internal temperature. Batt insulation, which is common in attics and crawl spaces, works well for container offices and living spaces. And finally, spray foam offers a functional climate-controlled space for temperature sensitive equipment storage.
OSHA is a regulation intended for workplace safety and not a residential safety code. With this in mind, single, mobile, container buildings, such as ground level offices, do not need the stairs to be OSHA compliant. As office structures expand, this may change. If you request a larger OSHA compliant container structure, we will prepare your structure accordingly.
Sanded wood paneling is a great option for companies that frequently relocate their offices and living spaces. The cabinet grade wood has a tight grain and smooth finish, so the walls appear smooth once painted. Trim strips cover the seams between two adjacent panels. Sanded wood paneling is also flexible enough to weather regular relocations without damage, making it ideal for field offices and mobile workforce housing.
PVC wall paneling is durable and easy to clean. The great thing about PVC wall paneling is that it’s moisture resistant. If a container will be used as a mobile bathroom, we usually install PVC paneling so the interior walls can be washed down.
In addition to wall paneling, drywall, aluminum, and perforated steel wall interiors are also available. Read more on shipping container wall paneling options here.
A shipping container’s floor is constructed of marine grade plywood or bamboo. “Marine grade” means that the wood has more layers than traditional construction plywood, making a more stable floor, less prone to warping. Additionally, container floors are not smooth and have small variations with counter-sunk screw heads. 40-foot shipping containers include a built-in trailer hitch tunnel, meaning there’s about a 10-foot-long steel plate on the non-door end of a 40-foot container.
When customizing the shipping container, many companies have the option to keep the original flooring and add an epoxy coating on top to make it easier to clean. Some companies choose to add new floors on top of the existing plywood or bamboo. These additional flooring options include coin vinyl, vinyl plank, welded steel, or aluminum.
A shipping container floor is 1.1 inches (28 millimeters) thick. Container floors are constructed with steel beams that lie at the base of the container and connect to the walls. These cross members lay roughly twelve inches apart. On top of the beams, manufacturers screw down panels of plywood or bamboo.
Shipping container floors are water resistant. The manufacturers who build shipping containers make sure that the entire box is water resistant and can travel by sea. Although, as we modify containers into a variety of structures, if water resistance is important to you, we recommend that you cover the original flooring with epoxy to improve the water resistance or install coin vinyl flooring or other water-resistant options.
At Falcon, we use a variety of paints. However, a hard, shiny alkyd enamel paint works well for most container uses. On the other hand, Falcon chooses to use a waterborne coating system that works just as well and is significantly better for the environment.
If you plan to add a mural to the container, a matte acrylic paint base is the best option. Industrial applications may call for specialized polyurethane paints.
To paint your container, you must select your paint based on the intended use of your structure, then, you need to prepare your container for the paint by paying special attention to rust patches and pressure wash off any dirt and dust. And finally, we recommend painting your container on a dry, sunny morning by either rolling or spraying your paint on the container.
While the steel exterior of shipping containers is resilient, rusting is possible. Rust may happen on the roof of a container where standing water or snow has accumulated for extended periods of time. To prevent this, make sure you properly maintain your roof as well as the walls of your container structure.
To install shelves in a shipping container, you must either weld or bolt the shelves onto the wall, depending on the interior of the unit. Consider bolting or screwing the shelves in place if the interior is built out with drywall or other applicable finishes. If the walls of the containers are un-modified, screw the shelves to the steel walls. When shelves are installed after delivery, we suggest screwing to the steel walls versus welding. Welding often burns away protective paint that can be both unsightly as well as harder to clean and repaint. Instead, after screwing shelves to the walls, any small screws that fully penetrate the steal can be ground off and painted to prevent rust.
Here at Falcon, we can install shelves into the container before we send it out for delivery. This way the work will be taken care of for you and, as you relocate the container in the future, the shelving will stay in place.
When shipping containers are placed side by side and the side walls are removed to create a larger room, it’s called a clear-span. Interior columns and beams maintain the structural integrity of the building.
Containers should be bolted together using special container connectors called bridge fittings, or they can be welded together in a permanent installation. If the structure is permanent, consider connecting the containers to the foundation as well. Seal the exterior vertical joints at the ends of the containers with caulk. Likewise, seal interior columns and overhead beams where the containers combine with polymer sealant and paint to match if desired. To finish off the interior, a long silver plate, called a threshold, should cover the floor seam between the two containers, sealed with screws and caulking. For the roof, ridge cap flashing must be screwed over the steel joint curb that we weld on at our factory.
Shipping containers were designed to be stacked nine high in ports and on cargo ships. For repurposed structures, shipping container buildings can also stack into multiple stories. For example, Fortress Obetz, a shipping container stadium, stacked containers three levels high.
An empty 20-foot shipping container weighs between 3,970 lb and 4,850 lb An empty 40-foot shipping container weighs between 8,340 lb and 9,260 lb Keep in mind that containers used to be heavier, so these numbers could change again in the future. Of course, the weight will likely increase with the addition of insulation, drywall, air conditioning units, and other elements.
A chassis is a frame on wheels that carries a shipping container. These trailers transport container structures to new locations. Some container structures permanently stay on a chassis for frequent relocation.
While it is possible to cut a shipping container in half, keep in mind that the stability of the structure comes from the four corners. If you choose to cut a shipping container in half for a project, here at Falcon, we would either weld the end cap back on to the open end or create structural reinforcements to ensure safety and stability. This technique is helpful for those container projects that have requirements outside the standard 10ft, 20ft and 40ft sizes.
A crane or a forklift is needed to move a container on or off a trailer. To determine whether to use a crane and a forklift, evaluate what equipment is available to you and where the container will be located.
To take the guesswork out of shipping container modifications, Falcon has developed standard floor plans for commonly requested container structures. These floor plans are predesigned container options that minimize confusion and are created with our customers’ needs in mind. Learn more about shipping container floor plans here.
Interested in taking the guesswork out of your design?
View our predesigned container floor plans here.
A 20-foot shipping container makes a great private office, storage unit, and industrial enclosure. Thanks to the smaller and more compact size of the 20-foot container, this box becomes a great solution for any application working with little space.
A 40-foot shipping container makes a great dual office, locker room, or living space – with applicable modifications of course. Although, the larger size allows companies to utilize the 40-foot units to become a variety of structures depending on the needs of the company.
Many companies opt to stack containers into two stories to create multi-unit buildings. Some companies choose to stack modified containers into military training units, stadiums, or other unique structures that require multiple containers.
The cost to modify a shipping container varies depending on the size and intended use of the structure. Falcon has placed pricing on each of our standard floor plan webpages to help our customers decide which solution is right for them. Browse our floorplans based on storage, workspace, bathrooms and locker rooms, industrial enclosures, living space, and multi-containers layouts.
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7717 Gilbert Rd.
Manor, TX 78653
877-704-0177
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