‘SHIPPING CONTAINERS AS BUILDING COMPONENTS’ By J. D. Smith V19.0 updated 30-04-06 University of Brighton Department of the Built Environment Supervisor: Noel Painting J.D. Smith © This work is licensed under the Creative Commons Attribution-Non- Commercial 2.0 England & Wales License. To view a copy of this licence, visit http://creativecommons.org/licenses/by-nc/2.0/uk/ or send a letter to Creative Commons, 559 Nathan Abbott Way, Stanford, California 94305, USA. J. Smith 2005-6 Shipping containers as accommodation II ABSTRACT This dissertation provides an assessment of the feasibility of using ISO shipping containers as building components. ISO shipping containers are widely available and as various pioneers have shown, can be a low cost building resource. The reasons why these units are not widely used in the UK is not clear. This document sets out to provide a view of the viability of this medium, together with an identification of problems that have occurred or may occur in implementing their use. It is the aim of this paper to show how shipping containers have been used, the methods employed, the locations in which they have been used and their purpose, this encompasses both the UK and also considers influences from the global market. The current housing needs of the UK is considered and the possibilities of satisfying this need using ISO shipping containers is assessed by means of a survey of existing container structures. This is followed by an analysis of the current UK Building Regulations (April 06) to identify the technical hurdles involved in container conversion. The research shows that the UK needs to increase its building output, quality and speed of erection. There are plentiful stocks of ISO shipping containers, and the use of these as building components could offer faster construct time and guaranteed quality, especially where the fit out is pre-fabricated prior to installation of the unit. Insulation design is a technical hurdle for the designer, as it can further reduce the already limited floor to ceiling height. In conclusion ISO shipping containers can offer a wide range of building types and configurations, which are only limited by the technical ability of the designer. J. Smith 2005-6 Shipping containers as accommodation II The research undertaken follows the logic path below. This shows how the research has evolved from the problems, to conclusion and recommendations: Problems Need for more building / housing stock Cost of new housing / buildings, Speed of construction, Speed of UK planning system Lack of usable land What are the key issues? UK governmental reviews More buildings required due to changing demographics Lack of skilled work force and longer predicted life Poor quality finish and cost Barker Report (Egan) spans (ODPM) of construction (Egan) Egan Re port Existing construction Population will continue to Building cost will increase due methods are to slow (Egan) increase (Barker) to demand (Barker) Prefabricated housing Opportunities ISO shipping Refurbishment of Build smaller Improved traditional Build upward to container units as existing housing (micro-homes) construction reduce urban spread a building stock components Availability of ISO Technical hurdles shipping containers Existing examples Key players Technical constraints: Technical standards for Building Regulations, ISO shipping size of units, containers transportation & planning Analysis Legend Problems Key Issues Governmental Reports Recommendations Conclusions Other Opportunities Research Path Figure 1. Research logic path diagram. J. Smith 2005-6 Shipping containers as building components III CONTENTS ABSTRACT.............................................................................................................................. II CONTENTS.............................................................................................................................III LIST OF FIGURES..................................................................................................................IV LIST OF TABLES ....................................................................................................................V LIST OF PLATES / PHOTOGRAPHS ....................................................................................V ACKNOWLEDGEMENTS .....................................................................................................VI DEFINITIONS AND ABBREVIATIONS ............................................................................ VII CHAPTER 1 INTRODUCTION..........................................................................................1 1.1 Scope of chapter.........................................................................................................1 1.2 Introduction to the research........................................................................................1 1.3 Identification of aims & objectives............................................................................5 1.4 Methodology (objective by objective). ......................................................................7 1.5 The methodology for each objective is defined below: .............................................8 1.6 Structure of research ................................................................................................10 1.7 Risk assessment........................................................................................................10 1.8 Limitations of the research.......................................................................................10 1.9 Literature review......................................................................................................11 1.10 Summary of chapter .................................................................................................23 CHAPTER 2 BACKGROUND INFORMATION.............................................................24 2.1 Scope of chapter.......................................................................................................24 2.2 History of shipping containers .................................................................................24 2.3 UK Highways Agency .............................................................................................27 2.4 What are ISO shipping containers made from? .......................................................27 2.5 What are the characteristics of an (ISO) shipping container ...................................28 2.6 (ISO) shipping container statistics ...........................................................................31 2.7 Summary of chapter .................................................................................................33 CHAPTER 3 KEY PLAYERS...........................................................................................34 3.1 Scope of chapter.......................................................................................................34 3.2 Architects .................................................................................................................35 3.3 Builders ....................................................................................................................45 3.4 Other.........................................................................................................................47 3.5 Summary of chapter .................................................................................................50 CHAPTER 4 QUESTIONNAIRES AND INTERVIEWS ................................................52 4.1 Scope of chapter.......................................................................................................52 4.2 Summary of chapter .................................................................................................63 CHAPTER 5 IDENTIFICATION OF TECHNICAL HURDLES.....................................64 5.1 Scope of chapter.......................................................................................................64 5.2 Guaranteeing container quality & structural integrity of second use containers.....64 5.3 ISO shipping container suitability for intermodal use .............................................64 5.4 Building Regulations................................................................................................66 5.5 Summary of chapter .................................................................................................75 CHAPTER 6 THERMAL MODEL OF A SHIPPING CONTAINER ..............................76 6.1 Scope of chapter.......................................................................................................76 6.2 Methodology ............................................................................................................76 6.3 Drawing of insulation types .....................................................................................88 6.4 Summary of chapter .................................................................................................89 J. Smith 2005-6 Shipping containers as building components IV CHAPTER 7 ANALYSIS OF DATA................................................................................90 7.1 Scope of chapter.......................................................................................................90 7.2 Analysis of survey data............................................................................................90 7.3 Analysis of technical hurdle data.............................................................................96