Shipping Container: Flat Panels UX2.0 for Sidewalls

This method to finish the long sidewall of a shipping container is for interior or exterior applications. The UX Flat panel and inserts is a two-step process insulated first with the (SWI) Side Wall Inserts to infill the wall's corrugated voids reducing the possibility of hidden wall condensation. The UX2.0 or the EXi 2.5  Flat Panels (48″ x 24″) are installed over the inserts so that the black studs run horizontally, crossing over the container's corrugations, providing maximum contact between the InSoFast studs and the steel container. This is the quickest and easiest method used when the container's condition is less than optimal.

1. 1. Preferred method when modifying older containers with dings and dents.
   2. When weld seams are greater than or less than 44" on center.
   3. Industrial fast track application.

Sidewall Bundle Contains:

• • • (UX2.0 Flat Panel) or (EXi 2.5  Flat Panels) = 40 sq-ft. per box. 
    • (SWI Side Wall Inserts) = 30 pieces 48 inches long covering 120 lineal feet of corrugation in-fill or (15) 8′ tall sections

First Things First

Safety Precaution: Cut out all openings in the container and complete any welding, cutting or grinding operations prior to installing InSoFast panels. Do not expose the foam insulation or plastic studs of InSoFast panels to the flames, heat or sparks generated by welding, grinding or cutting on the steel container after panels have been installed. 

See this page for in depth instruction for installing wood bucks. MORE

Determine your window layout first. We suggest that you adjust your openings to the right or left up and down to simplify other steps  later on. If you invested in a sample kit use the side wall insert to help you mark your layout lines.To fasten the interior half of the buck we used special fasteners fro ITW with a drill bit and metal wings that over drill the wood then break-off to allow the screw to anchor itself to the steel container wall.

The window bucks are complete and ready to finish. Next step is to insulate the interior walls with the Sidewall Inserts and the UX2.0 Flat panels.

The long sidewalls of the shipping container is a two step process and is insulated with Sidewall Inserts and either the UX 2.0 or EX 2.5 flat panel. 

Place a bead of adhesive in an “S” pattern down the center of the backside of the sidewall insert. Set the inserts into the lower half of the sidewall corrugations. Once in place seal the top of the insert with a bead of spray foam. Continue to cut, fit and glue all the insert onto the sidewall corrugations. Spray foam and seal all your work.

We recommend installing panels standing on end with the embedded studs running perpendicular to a shipping containers corrugated ribs. The goal is to provide as much contact between the studs and steel in order to maximize the holding power of the studs.

Start with a continuous bead of spray foam or adhesive along the bottom of the sidewall of the container.  Add a bead of PL Premium 3x along the inside corner where the first row of panels meet the corner of the container. This seals and locks the panel in place. You may want to trim the end of the UX or EX panel to “move” the stud down closer to the floor allowing a baseboard to be attached later during the finishes section. On the back of the panel, run a 3/8″ bead of adhesive along dove-tailed ribbing of each stud.For a standard 8’ high container, the panels can be installed in a stacked method or a running bond pattern. The running bond pattern works better to eliminate waste on a 9’ high container. Use the cut off end of the top panel to start the next column.Install the flat panels in a running bond pattern, (stagger joints like brick work.) We find that this method is the best practice for the straightest flattest wall. To start the second row, cut a panel in the center with a long snap off blade utility knife. This will start the offset running bond or staggered pattern.Cut and fit the panels around the window openings spray foam and fill all the gaps. Trim away excess spray foam after it cures with a razor knife.

The container wall is now ready to run electrical wiring or other in wall services.

(SWI Side Wall Inserts)

Side Wall InSerts One box of Side Wall Inserts covers 112 Lineal feet of corrugation.
Dimensioned to fit	48in x 7 3/4in x 1 1/4 in
Coverage	2.5 sq-ft
R-Value ASTM C518	R-5.3
Closed-Cell, injection-molded EPS	ASTM C578 Type II
Canadian Standards	CAN/ULC S701 Type 2
Foam Density	1.35 lbs per cubic foot

(UX2.0 or EXi 2.5 Flat Panel)

UX 2.0 Flat Panels 2″ thick of closed-cell, injection-molded EPS foam body achieves R-8.5 insulation The UX2.0 is our thinnest profile panel, optimized for  flat surface interior finishing. The UX 2.0 will work on floors, walls, ceiling and can be adapted for shipping container construction or other unique applications. It is a good choice as a base panel for the InSoFast PLUS when higher R-Value is needed.

EXi 2.5  Flat Panels 2 1/2″ thick of closed-cell, injection-molded EPS foam body achieves R-10 insulation. The EXi is optimized for interior finishing. The panel will work on floors, walls, ceiling and can be adapted for shipping container construction or other unique applications. It is a good choice as a base panel for the InSoFast PLUS when higher R-Value is needed.

Estimating and ordering is simple measure and add together how many side wall surfaces your container project requires to complete the job. Divide the total square footage (xx) by 40 sq-ft. this will determine the number of Flat panel  boxes required for your project, (round up to the whole box count).  Don’t overestimate.

• • One 2.0 Flat Panel (FP-2.0RW) = 8 sq.ft
  • One box of 5  - 2.0" Flat  Panels (FP-2.0RW) = 40 sq.ft
  • One boxes of 30 inserts 4' long (I-SWI) - covers 13 1/2' of the container wall 8’high)
  • See Diagram.
    • One side of a 20' container would need 1 1/2 boxes of the Side Wall inserts
    • One side of a 40' container would need 3 boxes of the Side Wall inserts

Don’t overestimate, cut studs and inserts can be re-used.

Loctite PL Premium

LOCTITE® PL PREMIUM® POLYURETHANE CONSTRUCTION ADHESIVE

Green Guard Certified Adhesive:

One of the many reasons we recommend Loctite PL Premium is it has the GREENGUARD Certification.  It is important to us that you use an adhesive that has low chemical emissions, you are building in an airtight shipping container, improving the quality of the air you breath is kind of important.

InSoFast panels were designed with simplicity in mind and we would argue that gluing them is not only the easiest method of installation but often the most effective. Third-party testing has shown the adhesive bond strength of our studs to have 108psi of holding power. This means each adhered panel is capable of holding over 5,000lbs!

In Canada the Glue is LePage PL Premium

Testing was conducted using Loctite PL Premium’s 3X Stronger Construction Adhesive, (in Canada it is marketed under the LePage PL Premium brand,) on clean concrete surfaces. It is the only adhesive we have tested. Other formulas and brands may not work as expected.

Estimating Adhesive Quantity

Estimating the amount of adhesive YOU will use has variables beyond our control like condition of your walls and how accurate are you with a glue gun? The example below is for one side wall of a 20' standard height shipping container you will need approximately 3 tubes of the adhesive. That is in a perfect world. PL Premium 3x adhesive is applied in a ⅜" bead on the backside of the studs onto the ribbed surfaces.  We realize that a 3/8" bead of glue is very subjective. It is important that there is enough adhesive to squish the dovetails on the back side of the stud when pressed to the container wall. Adhesive follows the "Goldie Locks rule, too much, too little, and just right. If you are doing just right you can expect that 1 large 28-fl oz tube will cover 18 of our 24" long studs or enough glue at a 3/8" bead to cover 36 foot long bead of glue. 

Additionally you will have to estimate for glue around openings like windows and doors.

1 large 28-fl oz / 828 mL tube = 18 (24" studs or inserts)

• CX 44 (22 panels with 2 studs each plus 8 end wall edges) = 52
• 52 ÷ 18 = 3 tubes of the adhesive

 To verify that enough adhesive is used, press the panel into place. Pull the panel back and check to see if the adhesive has spread out beyond the full width of the stud. It is normal for the panel to "float out" from the side of the container when it is accommodating irregularities in the container walls. Additional adhesive may be necessary in some areas.

Important Notice: Container Surface Temperature Applications

When bonding EPS and XPS foam insulation, use above 40°F (4°C) and avoid cure and surface temperatures above 90°F (32°C). Surfaces must be clean, dry and free of frost, grease, dust and other contaminants. Pre-fit all materials and protect finished surfaces. If using cartridge format, cut nozzle at a 45° angle to desired bead size and puncture inner seal. Be very careful not to allow Loctite® PL® Premium to cure on a finished surface.

Cold Weather Tips:  

Interior Installation

Heating the interior of the container will not be sufficient for the adhesive to cure because the insulation panels will not allow heat to transfer to the container surface.  It is recommended to either move the container to a heated area or tent and heat the exterior until the adhesive has cured.

Exterior Installation

The interior of the container can be heated until the adhesive has cured.

Interior and Exterior Installation

Install the exterior panels first while heating the interior.  Allow adhesive to cure before installing interior insulation.

Overview / Features / Technical Data / Directions

Wear gloves. Cured adhesive on bare skin will not come off immediately with washing and will cause skin to darken. Cured adhesive and discoloration will come off in about 3 days.

Clean tools and uncured adhesive residue immediately with mineral spirits in a well-ventilated area to the outdoors. Remove cured adhesive by carefully scraping with a sharp-edged tool.