Sandwich panel container – how to build a container from sandwich panels?
Sandwich panel containers are a proven solution for companies needing to quickly erect an office, welfare or storage facility. Construction is faster than traditional building, costs are predictable, and the finished module can be relocated if necessary. In this article, we show how to approach such an investment from a technical perspective and what to consider at the design stage.
Sandwich panel container – what actually is it?
This is a modular building based on a steel structure, the walls and roof of which constitute sandwich panels. The sandwich panel consists of two steel facings and an insulating core – most commonly made of foam PIR, PUR or mineral wool. Such a configuration provides a lightweight structure with good thermal and acoustic performance.
A sandwich panel container works well where assembly time and the repeatability of solutions matter. It can function as a site office, a porter's lodge, welfare facilities, a handy storage room, or a cold store. The modules can be connected together, so it is easy to expand the facility with additional rooms.
Sandwich panel container – how to make one step by step?
Construction starts with the design. You need to determine the dimensions, room layout, location of windows and doors, and insulation requirements. Only then are specific boards and profiles chosen.
Surface preparation
The container requires a flat, load-bearing base. Most commonly, a foundation slab, concrete pads or a steel frame set on compacted ground are used. Levelling is of great importance here – errors at this stage will carry over to the entire structure.
Steel frame installation
The frame is the skeleton of a container. It consists of bottom profiles, corner posts and top profiles. The components are welded or bolted together in accordance with the design. At this stage, it is worth checking the geometry – the diagonals must match.
Sandwich panel installation
The panels are fixed to the frame using self-drilling screws with EPDM washers. You start with the walls, then move on to the roof. The joints between the panels are sealed with tapes and silicone to eliminate thermal bridges.
Joinery and finishing
Once the structure is closed up, windows, doors and metal flashings are installed. Electrical, plumbing and ventilation systems are run inside. The internal walls can be made of thinner sandwich panels or plasterboard.
Construction of a sandwich panel container – what will be needed?
To carry out the work, you need a few groups of materials and equipment.
Materials
Wall sandwich panels (most commonly 60-100 mm), roof panels (100-160 mm), steel profiles for the frame, fixing screws, sealing tapes, flashings, window and door joinery.
Equipment
Crane or lorry loader crane for unloading and lifting slabs, drill drivers, slab cutting saw, laser levels, scaffolding.
Documentation
Technical design, certificates for the panels (reaction to fire, U-value), structural frame documentation. For permanent structures, a building permit or notification will also be required.
Sandwich panel office container – what should you look out for?
A sandwich panel office container must meet different requirements than a warehouse. Comfort of use matters – acoustics, temperature, and natural lighting.
When choosing panels, opt for a core with better insulation properties. PIR provides a low U-value at a smaller thickness, which translates to space savings and lower heating costs. For offices, mineral wool is also worth considering due to its acoustic performance and fire resistance.
Pay attention to ventilation. In a sealed module without heat recovery or air conditioning, an air quality problem will quickly arise. Also, make sure there is an adequate number of windows – natural light affects work comfort.
For facilities where employees spend the whole day, a raised floor with cable management works well. It facilitates subsequent layout changes.
Sandwich panel container – is it a good choice?
Obornicka board is a colloquial name for a sandwich panel originally produced in Oborniki. Today, this term is generally used to describe sandwich panels with an expanded polystyrene or polyurethane core available on the secondary market.
A container made of composite sandwich panels can be cheaper, especially if reclaimed material is used. However, one must pay attention to the technical condition of the panels – damaged facing, a damp core or deformed edges reduce the performance and lifespan of the structure. For temporary investments, this is a solution worth considering. For permanent buildings, it is better to opt for new panels with up-to-date certificates.
How much does it cost to build a sandwich panel container?
The cost depends on the size, finish standard and type of panels. As a guide: a basic 6×2.4 m welfare container costs from around ten to several tens of thousands of zlotys. An office container with better insulation, air conditioning and full equipment falls into the higher range.
Cost is also affected by transport, foundations and utility connections. With larger modular buildings, the price per square metre falls because fixed costs are spread over a larger area.
Where will a sandwich panel container work well?
There are plenty of applications. Construction site facilities, gatehouses by industrial halls, offices in logistics parks, handy warehouses, cold stores, staff amenities in production plants, guard huts in car parks. In agriculture – feed preparation rooms, technical rooms by cowsheds.
For main contractors and investors, modular containers are a way to shorten the schedule. A ready-made building is erected in a matter of days rather than months. And if needs change over time, the module can be dismantled and set up in another location.
If you are planning such an investment, choose sandwich panels to suit the specific function of the building and operating conditions. Insulation parameters, reaction to fire class and resistance to mechanical damage should be determined by the design, not by the price per square metre.