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by wigiv 2256 days ago
My company works with shipping containers daily - we modify them for industrial and manufacturing purposes. We reached out to the CURA team several weeks ago, offering our capacity if they scale/deploy their concept. They are currently building their very first pilot unit(s), so we'll see!

As a basic structural shell, shipping containers are great - plentiful, compatible with global logistics, cheap, dense/stackable. But, to bring them up to habitable standards, let alone medical standards, takes A LOT of work. Hard manual labor and also precision assembly work. We have some custom equipment to help speed that retrofit process for our own purposes, but most container mod providers don't - so while yes, you can deploy finished units anywhere, stack them densely and connect them quickly, there isn't a reserve of these units standing by, and you have no scaling advantage up-front in manufacturing them right now.

I'll add that by the time you retrofit insulation, ventilation, utilities and paneling inside (and you have to put this inside if you want to maintain side-by-side stackability and weather impermeability) what was a "decent" small room size becomes a bit claustrophobic.

For modular, dense, deployable, and durable emergency hospital facilities, it's best to look at one of the many architectural prefab approaches - volumetric, panelized, or otherwise. See: BLOX, Blokable, FullStack Modular, Katerra, etc. This field is growing rapidly, and many of these companies are already tooled to produce room and structure modules very efficiently.

Some pose the question of re-tasking hotels as temporary alternative medical spaces. I could see it for housing medical staff in a more dedicated and perhaps centralized manner, if nearby a hospital. There are several military slide decks circulating around that describe exactly what's necessary to create a field hospital out of a hotel/office - including ripping up the carpet in the entire facility, heavily modifying HVAC (central or standalone units) etc - and that's all doable, but I've wondered about the implications afterwards. You'd have to basically rebuild the interiors entirely, battle future customer perception ("Oh, the hotel that 100 coronavirus patients died in?") and I'm certain the insurance situation will not be straightforward...

5 comments

I would love to see a walk through of taking a container of unknown origin through a process to make it ready for a living space.

My uneducated assumption was that you walked into one and sprayed your sand/particle blaster at the interior surfaces until you've got raw metal everywhere, then you paint the interior with a metal sealant, followed by a powder coat. Then set up heating coils inside, take the interior temperature up to 210 to 220 degrees C, go back and remove the heating coils and then be ready to start installing flooring/walls what have you.

But I have no idea how practical that set of steps are, or even if they are sufficient. Hence the desire to see the process that someone has used successfully to prepare containers.

Can't speak to living spaces since we don't do that, but you have the basic process in mind. You might rip the floor planks/panels out entirely, eliminating the smelly, pesticide- laden lumber and giving access to more metal surfaces during blasting. Or, much less ideal but possible: you can seal over the nasty flooring with epoxy then leave it or put another flooring layer on top.

Haven't heard of powder coating interiors - that would be a lot of wattage! - but maybe doable with radiant methods and insulation blankets, or putting the whole thing in a giant curing oven? Most often it's just spray-on epoxy over rust-converting primer. There are low(er)-toxicity formulations out there. For undemanding applications you can paint with household enamel over primer - wouldn't hold up on the exterior though.

Interestingly, the Cor-Ten steel many (most?) containers are made of is a weathering steel that forms a protective rust layer when left to its own devices. So you could conceivably just leave it there to develop a fine rusty patina!

All told, there isn't a single "right way," to clean up a container, but there are some best practices and trends. YouTube seems to have a wealth of folks documenting their container home builds.

I'm no expert, but just looking at the hospital that got built so quickly in Wuhan [0], you can see that some sort of prefabricated modular construction units are involved. Do you happen to have more information on these?

0: https://www.bbc.com/news/av/world-asia-china-51348297/corona...

Structural modular with offsite prefab, for sure, but I don't know any specifics on the Wuhan hospital builds. From some other coverage, the units appear to have ISO corner castings, but the proportions don't look like 'normal' containers. There are other proprietary connectors for volumetric prefab - like Z Modular's "VectorBloc" - but these don't seem to be using anything fancy.

What stands out to me, watching the time-lapses: SO. MANY. WORKERS! They are everywhere on site, moving constantly, and the equipment never sits still either. That workforce, along with the certainty that zoning and environmental impacts weren't even a question mark show what the "command" side of a hybrid economy can pull off.

I always wondered where the containers were manufactured these days. I suspected China. And I found a nice video of a team doing so.

https://www.youtube.com/watch?v=rQfmanHKCn0

How long does it take to manufacture one? End to end, like in this video.

Is it possible to just pay a shipping container company up front to use materials that are more friendly for repurposing, with an agreement that you buy it after it is used? That way you wouldn’t necessarily need to strip and repaint it.
Certainly - the companies (mostly in China) that manufacture containers will do one-offs. They can be specified with less toxic epoxies and composite/alternative flooring, and any cutouts or other features you want to end up with. This avenue is expensive though. You don't have the economies of scale in comparison to "standard models" pumped out by the tens of thousands, and you don't have the advantage of shipping the container over full of goods instead of empty. Caveats abound, of course.

If one wants to avoid stripping paint and floors out of secondary market boxes, it's also possible to buy the constituent pieces of a shipping container individually - the corrugated sidewalls, doors + fittings, floor channels, corner castings etc - unfinished or with primer only. In this way, you can ship one or more deconstructed shipping containers INSIDE a shipping container! But then you have to fixture it and weld it etc, so you're back to losing economy of scale...

For our purposes, we usually use 1-trip/low-trip for client projects avoiding the nasty ones by careful selection, and we have a custom machine that media blasts the interior and exterior down to bare metal when we work with older WWT and partial/damaged containers of unknown heritage.

I've seen whole hospitals converted to hotels so I don't think that's a huge problem unless you start advertising it.