Here’s the product(s) that’s suited for your job
CX Panels, Side & End Wall Inserts, Ceiling Inserts
Container InSerts are a specifically shaped sleeve of EPS foam designed to fill the inset corrugation of a shipping container. They are intended to be used in conjunction with InSoFast Panels to achieve maximum insulation and air-tightness in minimum space. InSerts can be adhered directly to the metal with PL Premium 3X.
Here’s documentation and guides catered to your project
Ensure all surfaces are clean of any debris, dust, loose paint, etc before installing panels with PL Premium 3X adhesive. PL Premium 3X can span gaps up to 3/8″ and larger gaps can be backfilled with spray foam. These methods can help solidify an installation over dented areas of a container, however, it is best to start with as much surface contact as possible. If your container has large dented areas, we recommend hammering them as smooth as possible before your installing InSoFast products.
PL Premium 3X Construction Adhesive
We have tested and recommend PL Premium 3X Construction Adhesive. Other formulas and brands may not work as expected. Please ensure adequate time for the adhesive to set and cure before attaching finished materials such as drywall and cabinets. PL Premium is a moisture-cured glue. Under dry conditions with low relative humidity, the adhesive may have trouble setting. As plastic and steel have very low moisture retention, you may want to lightly mist the panel with a spray bottle of water to expedite the curing process. Do not over-mist the panels. It may be necessary to brace panels and inserts against the wall while the adhesive sets.
Install InSerts before panels. Run a bead of PL Premium 3X adhesive along the length of the InSert and press into the inset space of the shipping container’s corrugated wall. You can use duct tape to hold the InSerts in place until the adhesive has set or until you are ready to install InSoFast panels.
Install panels on the ceiling before installing along the walls. This way the ceiling panels will sit on top of the wall panels where they meet, adding additional bracing support for the ceiling. The same concept should be applied to finish materials such as drywall. You can increase the holding power of a ceiling by backfilling cavities with a small amount of spray foam adhesive in addition to running PL Premium 3X along the studs. We recommend using a professional applicator gun for a controlled flow of spray foam. Warehouse Bay Corporation is a good place to purchase these materials. Brace panels firmly until all adhesives have cured.
We recommend installing panels with the embedded studs running perpendicular to a shipping containers corrugated ridges. The goal is to provide as much contact between the studs and steel in order to maximize the holding power of the studs. On the back of the panel, run a 3/8″ bead of adhesive along dove-tailed ribbing of each stud. You can run an additional bead of adhesive along the foam body of the panel in sections that will contact the container or in a general zig-zag pattern. The following procedure sets up the running bond or staggered interlock pattern. Installation follows the same format described in greater detail under the Resources > Interior Guides section of this website with the exception of the panels being installed vertically along the wall:
- Set the first panel in a corner with studs running perpendicular to the direction of the corrugation.
- Cut the second panel along one of the marked cutting lines and use a section to begin the second “column” along your wall. The other section can be used for the same function later on the wall.
- Complete the first two columns sequentially with panels. Cut as needed.
- Repeat the previous steps creating staggered panels to complete as many columns as required.
Preventing Moisture Issues
Metal is thermally conductive. Do not penetrate the steel walls of your container with screws or fasteners. This compromises the continuous seal and can introduce moisture-related issues. Use an expanding spray foam to completely seal any gaps and cracks around the panels such as near doors and windows, along the top and bottom of the walls, or around outlets.
Indoor Air Quality (IAQ)
A shipping container is almost inherently airtight due to its materials and construction. We recommend maintaining these qualities in your design because it will result in a highly energy efficient home. However, in order to be done properly and maintain indoor air quality, your mechanical equipment (HVAC) must be designed specifically to adjust for fresh air circulation.