Shipping Container: Flat Panels and Sidewall Inserts

Before You Glue

This method to finish the long sidewall of a shipping container is for interior or exterior applications. The CON-SWUX 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.

The flat panel the studs run horizontally, 24" wide x 48" high this will change how you typically fasten your finishes and cabinets.  This stud spacing is perpendicular to the 4' x 8' standard construction  practices!  The panel's stud spacing is 16" on center horizontally.  THIS EFFECTS the finish materials installation methods.

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. 

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. 

Dry fit and adjust your panels to fit. Use a razor blade knife to fit around cargo hooks, dents, and weld seams. Leave a 1/4" gap to allow for spray foam sealant.

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.