The Endwall of the shipping container is a two step process and is insulated with Endwall Inserts either the UX 2.0 or EX 2.5 flat panel. These panels are 48″ x 24″ and are installed on end wall.
Install either the UX 2.0 or EXi 2.5 Flat Panels
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 flat 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 Flat Panel 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.
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.
Start with a continuous bead of spray foam or adhesive along the bottom of the end wall of the container. Next lay a bead of adhesive in an “S” pattern down the center of the backside of the End Wall Insert. Set the inserts into the lower half of the end wall 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 into the end wall. Spray foam and seal all your work.
Add a bead of PL Premium 3x along the corner where the first row of panels meet the corner of the container.
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.
You may want to trim the end of the UX or EX panel to “move” the stud down closer to the floor allowing baseboard to be attached. 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.
Seal the gaps at the tops and edges of the corners with spray foam.
We do not recommend installing UX 2.0 or EX 2.5 panels without the Inserts. The Inserts are needed to prevent convective looping behind the wall. If the end wall inserts are not used, seal the corrugation with spray foam at every 4’ height horizontally to minimize the convective loop.
How To Links:
The Recommended Adhesive
Loctite PL Premium
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.
|LOCTITE® PL PREMIUM® POLYURETHANE CONSTRUCTION ADHESIVE Rough estimate for 28 ounce tubes of adhesive required|
|Container||CX 44 Side Walls||End Wall and Inserts||Ceiling and Inserts||Swing Doors||Floors||Total without doors and floors||Total Estimate with doors and floors|
|20' Standard||3 Per side total 6||2 1/2||6 1/2||3||7||13||23|
|20' High Cube||3 Per side total 7||2 1/2||6 1/2||3||7||14||24|
|40' Standard||6 Per side total 12||2 1/2||13||3||14||28||45|
|40' High Cube||6 Per side total 13||2 1/2||13||3||14||29||46|
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:
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.
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.
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.
PDF Instructions and other Guides
InSoFast Plus Method
Need a higher R-value? No Problem! Start with a base of InSoFast continuous insulation panels they are feature-rich and easy to install. Then add rigid foam insulation over top of InSoFast panels.