Container Conversions: Modifications

Cutting a piece out of your shipping container is necessary if you plan on

creating a passage between the containers or you plan on adding
windows and/or door openings to the container walls. There are many
ways to cut through container steel, including a plasma cutter, cutting
torch, grinder, and a jig saw (for small openings). If you have no
experience cutting steel or welding, the best route to go would be to hire
a welder. Before removing any structural components, it is vital to secure
reinforcements because when you start cutting containers up, they
become weakened. Cutting a shipping container or removing panels
causes the structural integrity to be compromised. As a general rule,
whenever you remove parts of the panelized corrugation, steel framing
will be necessary to frame out the opening. In addition, column and roof
support may be required depending on the size of the opening and
roof/wind loads. Be sure to review with a structural engineer or architect.

Container Alliance has extensive experience in basic container modifications and can cater to essentially any need that might come
up with regards to cargo container conversions. We specialize in preparing containers for various applications that involve the
cutting of container sections in order to join them together with others. We have removed entire sidewalls, portions of sidewalls,
floors, and ceilings.

Doors and Windows

Container Alliance can cater to essentially any need that might come up with regards to
custom shipping containers. We have qualified modification experts that can source
anything you need to meet your specific requirements. An experienced fabricator and welder
use a welding gun to cut doors and windows into the steel side. Windows can range from a
small porthole to a fully glazed window wall that can be opened to create access to the
entire side of the container. If your modified shipping container is being used as a business,
it might be a good idea to add sliding hatch or a sliding steel door.

Container Alliance steel sliding doors were created as an alternative to roll up doors when
full size wall height is needed and can be installed on either side of the container. Another
great thing about this door is that it is virtually invisible when the container is shut and can
be locked from the inside, making it very safe and secure. These doors are very heavy and
industrial, perfect for workshop applications, mobile product display or “pop up” store fronts.
The commercial lightweight door is cost effective, secure and durable, and can be installed
 on either side or front-end wall of the container. You have the option of having the door open
outward or inward with hinges on either side. All openings for doors and windows should be
reinforced by steel framing. If you are converting a container into a home, french doors are another option. Skylights are another
great way to bring in natural light without running electrical or mounting lights inside your container. Modify your shipping container
with domed, flat, or vented skylights, as well as custom sized skylights from Container Alliance.

   
Flooring
The wooden floors of shipping containers are usually treated with pesticides, so it is necessary to either replace them or create a
physical barrier with epoxy resin and optionally build a new plywood subfloor on the top of them. When modifying shipping
containers, most people replace the flooring rather than just cover it up, but sealing the floor with polyurethane or epoxy paint is a
good idea as well. Most importantly, be very careful if you decide on sanding the floor. Sanding can release trapped fumigants and
the exposure could be dangerous. You can find out the history of your container on the data plate. The data plate reveals what the
floors had been treated with previously. The chemicals used to treat the plywood floors can potentially be harming to the health of
humans, so replacing the floors might not be a choice if you are planning to live in your container or conduct business on a regular
basis. Why is the vapor pressure important?  It’s easy to trap the contaminated floors of a shipping container to prevent physical
contact, but it’s very difficult to block their vapors if present and their subsequent inhalation.

Before applying the epoxy, it is a good idea to wash the floors with isopropyl alcohol to remove any surface chemicals or oils that
would prevent the epoxy from penetrating and sticking to the wood. Make sure you have a well-ventilated area because the alcohol
vapors can be potent. The epoxy should be both a physical and vapor barrier to the chemicals. An optional subfloor can be added to
provide additional barrier to the treated chemicals. If you are building a separate subfloor in your cargo container conversion, make
sure you seal the existing treated wood with solvent-free epoxy resin using a paint roller. You can then build a subfloor on top of this
if desired. Another interesting option I have seen in cargo container conversions is to pour a concrete floor inside the containers on
top of the plywood. It could even be the finish floor with some dyes and/or patterning added.

Alternative Flooring

Bamboo Floors– Unfortunately, the tropical wood used in containers is becoming

scarce and in danger of running out. It takes about 50-60 years to replace one cut
down tree. Bamboo is now being used as an alternative to plywood by select suppliers
to make shipping container floors to help decrease the environmental damage.
Bamboo is biodegradable and has the ability to grow rapidly. As bamboo grows, its
grass naturally fights off pesticides and other harmful chemical

Steel– Steel is one the most recyclable

products in the world and last a relatively long time before it needs replacement. Steel is
durable and a sustainable flooring solution. Steel is resistant to rust, wear and tear
caused by heavy use, as well as corrosive environments.

Carpet– Carpet will provide an added protective layer that will feel good in between your
toes. Carpet tiles are perfect to cover the traditional hardwood flooring instead acting as
a replacement option. Carpet tiles come in a variety of sizes and styles and can be
installed in odd shaped floor spaces. They can be installed in small areas and in many
different ways. Carpet tiles are flexible, affordable, and a practical alternative to
container flooring.

Vinyl–  Vinyl flooring can last anywhere from 10-20 years. Vinyl is resistant to scratches and stains. It is easy to clean and resistant
to rust, oil, and water. Vinyl makes your living space easy to maintain by sweeping on a regular basis and  occasionally mop when
necessary.

Linoleum– This is one of the most eco-friendly alternatives and is naturally antibacterial and biodegradable. Linoleum floors can last
up to 40 years with regular maintenance and care.

At Container Alliance, we have found that many customers prefer a different flooring material. We have various flooring options
including our standard options: steel overlay, vinyl flooring, Rhino lining®, or rubber flooring. Call us today to discuss these various
flooring options for your modified shipping container.

Cleaning, Sanding, and Painting

Cleaning:

Make sure to remove any dirt, dust, or other forms of detritus

Wash the container. Use a pressure washer or high- powered spray brush and completely clean the inside and outside of the
container

Inspect the inside and outside of the container for any rust or corrosion.

After the container is dry, go over the container with medium grit sandpaper.

Apply a primer coat of paint

When primer is dry, apply a thick, exterior paint.

Paint:

Applying the paint by using an industrial paint sprayer can make the job fast and easy. However, if you cannot get one, rolling the
paint will work just as well. There are direct to metal and oil-based paints that will fit your needs. One of the most recommended is
an industrial, alkyd enamel. You will probably need to give the container at least two coats of paint. Painting the floors can help seal
it off and prevent both water damage and the idea of fumes. Any outdoor paint will work, we recommend Behr Porch and Patio
paint. This type of paint is designed to be walked on and withstand the weather of all four seasons. Treating any rusted areas with
vinegar and repainting the container with DTM paint will help the unit withstand weather, and a thick coat of porch and patio paint on
the flooring will help to prevent the floor from rotting or releasing fumes.

Painting at Container Alliance

At Container Alliance, we take pride in the modification work that we do.

The most common type of general alteration of an ISO unit is
refurbishment and painting. Starting with used or new containers, our
refurb/paint process is not just cosmetic; we spend time in the preparation
of the unit prior to applying any coating. This includes pressure washing to
remove any dirt or dust, grinding down surface issues and straightening
out any blemishes or dings. From there, we primer any steel that we may
have exposed in an effort to preserve the life of the container. Next, we
tape off the rubber seals around the cargo doors for longevity, but keeping
in mind the aesthetic of the unit as well. Finally, we spray with direct to
metal water-based paint. The finished product is a high quality freshly
painted container. We can also apply specialty roof coatings customizable
to your specific application.

Fixtures, Electrical, Plumbing

Framing the inside of your container is optional. However, framing and drywall give the interior a more natural feel and can aid with
the insulation. At this point, you should be adding any exterior doors, as well as any skylights and flashing required to weatherproof
the structure. Now, it is time to install plumbing, electrical, and heating systems. Contact a trained specialist if you are not familiar
with setting up these systems. If you are installing electrical, plumbing, and a heating system yourself, it important to plan and mark
where everything is going to go. Where are your switches, outlets, and lights going to go? Where are the appliances going to
placed? Where is the fuse box going to be placed? Ask yourself these questions and create an electrical layout. If you are
concerned about security or live in a remote area, do not install an electrical outlet on the outside of your home.

Electrical at Container Alliance

We can do electrical packages for any size container. We do offer standard packages
and can add or subtract from the package. Of course, as with anything in our custom
shop, we can accommodate anything outside our standard configurations, just give us a
call and we will take care of the rest!

Insulation
Insulating your container especially in cold climates is necessary, so that condensation
does not easily form on the interior steel walls. This could result in future problems such
as corrosion and mold. Insulating the walls can be done on the inside or outside or both,
just as long as it is insulated. Insulating the outside of the container creates a more
conventional look to your structure and allows you to use the full space of the container.
Insulating the inside of your container gives the outside a more rugged look because of
the steel exterior with a more conventional interior. Spray form may be the most
expensive, but the benefits outweigh the financial costs. Polyurethane foam for the interior and ceramic insulation paint for the
exterior, work well together. A minimum of a two inch foam layer creates structural support and stops the condensation from building
up. Applying a foam layer to the interior and exterior walls will create protective barrier against the heat, cold, and moisture. For hot
climates, reflective paint on the exterior will help reflect the sun’s UV rays and prevent heat from being captured. The paint also
helps to obstruct mold, mildew, and rust from forming on the container. Steel or wood studs are used with the spray foam to secure
drywall. Incorporating a thermal break between the studs and container walls
will help the heat stay in. Drywall will give the interior a more traditional feel and
will add insulation. 

Types of Insulation:

Spray-on

Roll-on

Ecological insulation, such as egg cartons, etc.

Insulating at Container
Alliance

Our insulation packages are always very high quality. There are many different types of
insulating products that are available, from glue-on panel systems to insulating paint.
Our standard insulation is done with R-13 value fiberglass surrounded by wood studs,
and finished with plywood and drywall or particle ply. Always ask a sales rep about
 what you need, and we can work with your custom requirements.

Ventilation
Managing airflow and ventilation in your modified shipping container is equally as important as insulating your container. Be aware,
due to the size of containers, any ventilation problem is enhanced. Without providing proper and effective ventilation, serious
problems will occur in the future. Shipping containers are meant to be air tight  because they are used to ship goods around the
world in various weather conditions. Here are four venting options to manage the airflow and temperature in your container:

Pre-installed container vents. Containers already have passive vents installed in them. They allow for pressure changes when the
weather quickly changes and have a screen to prevent insects from getting in. However, they do not promote airflow through the
container.

Louvered vents. Louvered vents are added to create more airflow and helps to cool the
container. They also help fight against too much moisture from building up. It is a good
idea to install them on opposite ends to help promote as much airflow as possible. 

Turbine vents. Turbine vents will help if you are having moisture problems by moving
the moist air up and bringing the less moist air down. The vent will turn and then pull
moisture up and out. However, turbine vents can
also allow moisture back in.

Heat/ AC units. If you are more interested in the

temperature in the air, a heat/ac unit will do the
trick. These units can ensure that your container
will be toasty in the cold and snowy winters, but
keep cool in the hot and humid summers.