See

discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/232956697

Use of refurbished shipping containers for

construction of housing buildings: details for
structural project

Article in Journal of Civil Engineering and Management · January 2012

CITATIONS READS

2 7,438

3 authors, including:

Luís F.A. Bernardo Luiz Antonio Pereira de Oliveira

Universidade da Beira Interior Universidade Ceuma (UNICEUMA), Brazil
42 PUBLICATIONS 328 CITATIONS 84 PUBLICATIONS 468 CITATIONS

SEE PROFILE SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Influence of Transversal Reinforcement on Plastic Rotation Capacity of High-Strength Beams View

project

Polymeric Composites Reinforced with Alumina Nanoparticles View project

All content following this page was uploaded by Luiz Antonio Pereira de Oliveira on 16 May 2014.

The user has requested enhancement of the downloaded file.

 JOURNAL OF CIVIL ENGINEERING AND MANAGEMENT
ISSN 1392-3730 print/ISSN 1822-3605 online
2013 iFirst: 1
19
doi:10.3846/13923730.2013.795185

USE OF REFURBISHED SHIPPING CONTAINERS

FOR THE CONSTRUCTION OF HOUSING BUILDINGS: DETAILS
FOR THE STRUCTURAL PROJECT

L. F. A. Bernardo, L. A. P. Oliveira, M. C. S. Nepomuceno, J. M. A. Andrade

Department of Civil Engineering and Architecture, University of Beira Interior, 6201-001,
Covilhã, Portugal
Received 31 May 2011; accepted 14 Dec. 2011

Abstract. Construction using refurbished shipping containers is a recent building system, with already many
successful examples around the world. This system presents a huge potential in the field of sustainable construction
provided by the recycling of used containers. This paper aims to contribute to a better knowledge of this
construction system in what concerns to the structural project. The general constitution of two maritime shipping
containers is presented as well as some aspects of their structural behavior. For this purpose, numerical analyses
were performed using a finite elements analysis program. Normative aspects for the structural project are also
presented. This paper also presents the analysis of a case study with the use of refurbished shipping containers to
build a single-family house. The evaluation of the strength of the refurbished shipping containers to building
actions is carried out. It is shown that such evaluation is not easy because some mechanical parameters of
noncommercial steel section of the elements that compose the shipping containers are unknown. Nevertheless, this
study shows the feasibility of this building system.
Keywords: construction system; shipping containers; structural behavior; finite elements analysis; case study.
Reference to this paper should be made as follows: Bernardo, L. F. A.; Oliveira, L. A. P.; Nepomuceno, M. C. S.;
Andrade, J. M. A. 2013. Use of refurbished shipping containers for the construction of housing buildings: details for
the structural project, Journal of Civil Engineering and Management http://dx.doi.org/10.3846/13923730.2013.795185

Introduction given to the containers manufactured in accordance

with ISO norms, which ensure uniformity in what
The economic recession period that we are currently
concerns to their mechanical and geometrical char-
passing by, especially in Europe, as leaded to a signi-
ficant reduction in the exchange of goods by sea. acteristics.
Consequently, the accumulation of shipping contain- In the market, there are shipping containers with
ers at seaports, mainly in importing countries, has several external dimensions. The most common ones have
increased. This has led to problems of space allocation lengths with 6.0, 9.0, and 12.0 m and heights with 2.4,
(Pisinger 2002). This was one of the reasons that have 2.55, and 2.7 m. The width is usually 2.4 m. For housing
triggered the start of use containers for the construc- buildings the most commonly used containers have 6.0
tion of housing buildings. In a generalized panorama and 12.0 m long and 2.7 m high because it provides a
of economic crisis, construction based on the reuse of bigger ceiling height. Such containers are called HC
shipping containers can represent a new important (High Cube), with commercial names as 20’HC (6.0 m
market niche. or 20 feet long) and 40’HC (12.0 m or 40 feet long).
Containers are designed to carry and bear very The main structure elements of the shipping
high loads, as well as resist to aggressive environments containers are made of steel. They incorporate trape-
during a lifetime of 15 years or more (Nunes 2009). zoidal metal sheets to form the walls and roof and
For example, one of the requirements imposed by ISO profiles to form the ‘‘box’’ edges and the grid to
norms is that the containers should be able to support support the wooden floor. The corners have rigid
at least other six containers over with maximum load pieces to support the container and to allow the
(ISBU 2009). Among different types of containers connection between containers. The door is located in
existing on the market, special attention should be one of the smaller faces.

Corresponding author: L. F. A. Bernardo

E-mail: [email protected]

1 Copyright ª 2013 Vilnius Gediminas Technical University (VGTU) Press

www.informaworld.com/tcem
2 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

By using old shipping containers, this construc- “ ISO 3874:1997
Series 1
Container shipping.
tion system contributes for the recycling and con- Handling and safety;
struction sustainability (Vijayalaxmi 2010; Lun 2011). “ ISO 830:1999
Freight containers
Vocabu-
Many constructions based on the use of shipping lary.
containers already exist all over the world in many
countries for over a decade (South Africa, Australia,
2.2. General characteristics
USA, Holland, Japan, New Zealand, and UK, among
other, as reported by Webb 2006; Murdock 2009; The containers analyzed in this study are designated
Nunes 2009). Most of those constructions are housing by ISO as 1AAA and 1CCC, also known at the
buildings, such as single-family and multi-family market as models 20’HC and 40’HC (Fig. 1),
buildings, residence halls or dormitories. Many exam- respectively. The height of those containers (2.71 m)
ples can be found in architectural literature and enables a minimum clear ceiling height of 2.40 m.
websites. Also buildings with other functions, particu- This value respects the minimum required by many
larly for commercial, hotel, tourist, business and national codes for the construction of housing build-
public sectors, such as offices, corporate offices, ings. Table 1 presents the main characteristics of the
studios for artists, restaurants, cafes, hotels, apartment containers.
hotels as well as museums and schools constitute other As illustrated in Figure 2, the containers are
possible cases to use this construction system. How- composed by the front face (1), the face of the door
ever, costumers and promoters still fear this new (2), two sides (3), roof (4), and the base structure (5).
construction system in many countries, namely in The containers are composed with several ele-
Portugal. ments (Fig. 2, Tables 2 and 3), including several steel
The remodeling process of the containers profiles to form steel frames. The front and side walls
should be held in factories to guarantee quality include trapezoidal sheets (cold formed) with vertical
control. This phase includes all the preparatory ribs and thickness ranging between 1.6 and 2.0 mm.
works such as disinfection and cleaning, openings, The roof is made with trapezoidal sheets (pressed)
strengthenings, connections, surface preparation, with ribs. The doors, made of two leaves, are
painting and, eventually, also the implementation of composed by a frame and sheets. The leaves are
installation networks. To guarantee the success of
connected to the gate of the container with two
this phase, project must include all necessary details
hinges. Almost all profiles are made of cold-formed
for the preparation of the containers, in order that
steel sections, with steel plates whose thickness varies
no problems occur in the construction site during
between 4.0 and 6.0 mm.
assembly. In the final phase, containers are trans-
The floor is in plywood (thickness 28 mm)
ported to the construction site to be positioned and
supported by a steel grid, which constitute the base
connected.
structure. This structure is formed of several cross
members (BCM) and two bottom side rails (RDB).
1. Relevance of the subject For handling, containers include opening fork pocket
Papers focused on the structural field of buildings (FP).
construction system with the use of refurbished The front face is composed by two trapezoidal
shipping containers are rare. Most of the existing sheets (front end wall
few) jointed through auto-
literature focuses mainly on architectural aspects. This matic welding to form a panel welded to a frame
paper intends to contribute to a better understanding which is constituted of several profiles: an upper front
of this construction system. Structural behavior and header (FH), a lower square steel tube (front sill

some elements for the civil engineering project are FS), two vertical corner posts (FCP) and four corner
focused in this paper. pieces.

2. Description of containers 20’HC and 40’HC

2.1. General characteristics
The following list includes important ISO norms for
shipping containers to be consulted by the engineer:

“ ISO 1496-1:1990
Series 1
Container ship-

ping. Specification and testing
Part 1: Con-
tainers for marine applications in use;
“ ISO 668:1995
Series 1
Container shipping.
Classification, dimensions and calculations; Fig. 1. Containers 20’HC and 40’HC
Journal of Civil Engineering and Management, 2013, iFirst: 1
19 3

Table 1. Characteristics of containers 20’HC and 40’HC

Load capacity
Length (m), Width (m), High (m), Capacity
Model internal/external internal/external internal/external Self-weight (kg) Total (kg) Surf. (kg/m2) Volume (m3)

20’HC 5.9/6.0 2.34/2.40 2.71/2.89 2300 28,000 867.63 37.41

40’HC 12.0/12.2 2.34/2.40 2.71/2.89 2300 36,000 1229.51 76.10

The door face is composed by one frame which Based on this section, we can conclude that the
includes a lower door sill (DS) made with a channel constitution of a shipping container is very complex.
section, two vertical corner posts (DCP) built with a Most of the elements are made of profiles with
channel shape in hot-rolled steel and another one in noncommercial sections. The terminology used in
cold-formed steel welded together to form a hollow this section to designate many elements follows ISO
section, an upper door header (DH) composed by an norms for container vocabulary.
inner ‘‘U’’ and an outer shape made of cold-formed
steel welded together to form a hollow section, four 2.3. Materials
corner pieces and secondary elements of the door
Corten A steel compose most of the components of
locking devices.
the containers. Only profile DCP is made with steel
Each door leaf includes a sheet welded to a frame
SM50YA. The characteristic values of the yielding
with a locking device, two hinges, seals, and supports.
stress (fyk) are 343 MPa (Corten A) and 363 MPa
The doors are usually removed and used as secondary
(SM50YA).
elements of construction; therefore, they are neither
described in detail nor considered as main structural
elements in this paper. 3. Evaluation of prevailing forces in containers
The lateral faces are composed with an upper The evaluation of the prevailing forces in the elements
square steel tube (top side rail
TSR) and the side of the containers, in order to apply normative criteria’s
wall (sw) composed of several trapezoidal sheets held (Section 4), was accomplished with an elastic analysis
together by welding. For model 40’HC, the thicker of the containers under typified loading. To achieve
sheets (external) were designated by sw1/sw3, while this goal, numerical models were implemented through
less thick sheets (internal) by sw2. For model 20’HC, the finite element analysis software LUSAS (2010).
external and internal sheets were designated by sw1 The spatial geometry of the containers was
and sw2, respectively. defined taking into account the location of the steel
The roof consists of pressed steel sheets joined by profiles axes. The linear elements were modeled with
automatic welding. Such sheets are generally not linear finite elements (thick beam) with linear inter-
considered as structural element once ribs don’t exists polation. For each element, the geometrical properties
near the top side rail. of the gross section were introduced. Such properties
Containers also include many local strengthening were calculated manually. Table 4 present the most
plates. The joints between the several elements that relevant geometrical properties of the gross section of
compose the containers are made by continuous the elements, namely area (A), moments of inertia (Iy
welding. and Iz), and shear areas (Asy and Asz) with respect to
the coordinate axes y and z. For the orientation of the
axes, Eurocode 3 Part 1-1 (2006) convention was used.
Because the sections of the elements are very slender,
torsional stiffness is very low, so this parameter was
considered negligible. The shear areas (Asy and Asz)
were allocated to the straight segments of the section,
so curved corners were neglected (Fig. 3).
To model the side sheets of the walls (sw and few)
quadrangle plain finite elements were used (thick
shell), with the thickness (e) of the respective plate.
However, as the sheets are trapezoidal, it presents a
higher rigidity in the vertical direction (orthotropic
sheet), so bar elements were added to simulate the
increase of rigidity in such direction. The spacing of
such elements (Fig. 4) is 30 cm (average spacing
between the ribs of the sheet). The sections of these
Fig. 2. Containers composition bars were calculated so that the stiffness of the
4 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

ensemble (flat sheet bar) in the vertical direction is Figure 5 illustrates the numerical models imple-
equal to the rigidity of the trapezoidal sheet (Table 5). mented with software LUSAS. For the support con-
The cover plate was modeled using plane ditions, it was assumed that all the translations in the
finite elements because it has no ribs near the four lower corners were restrained, because containers
supports (see Tables 2 and 3). An equivalent thickness are designed to be supported by the corner pieces. A
was calculated to ensure the same sectional area per Young’s modulus of 210 GPa and a Poisson’s ratio of
unit length (2.17 mm). 0.30 were assumed.

Table 2. Elements of the shipping container 20’HC

Designation /Illustration Transverse sections of the components

Base structure
BSR
BCM1 BCM2 R9

4 4

122

122
4,5
R4

R4

,5
R4
45 45
30

few
18
Frontal face
2
45,6

R2

71 110 104 250 250 110 52

1019

FCP
FS

56
FH
R4
3 R3
60

4
152

153

60 56
R8
6

45

12 174
R

Door face
56
12

R6
DCP
40

6
46
R1

230
2

R9
28
3

28

45
140 4.5
138

DS DH 4
R4.5
R4
R8
110
65

sw1

Lateral face
36

29 68 140 70 278 278 68 72 68 34

Journal of Civil Engineering and Management, 2013, iFirst: 1
19 5

Table 2. (Continued)
sw2
1110

36
1.6

34 68 72 68 70 278 278 68 72 68 34

3 R3

60
TSR
60

Roof roof

45.5 91 91 91 91 91 91 91 91 91 45.5
13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5

Eight loading cases (Table 6), concentrated and combined with moderate bending moments and shear
linear, were considered. These cases aim to simulate forces.
possible situations of loading transmission between The global results show that containers have a
containers and between these and other structural rigid behavior. Such behavior can be explained by the
elements. The cases with concentrated loads (load continuous connection between many of the elements
cases 1, 3, 5, and 7 illustrated in Table 6) intended to of the container.
simulate situations where the containers are connected
together only by the corner pieces. The cases with 4. Code’s provisions for safety verification
linear loads (load cases 2, 4, 6, and 8 illustrated in To verify the safety of the structural elements of the
Table 6) intended to simulate situations where the containers, the structural engineer must follow struc-
containers are continuously connected to each other tural codes that rule the design of structures. In this
(horizontal loading) or simulate vertical reactions of particular case, for steel structures and for the
slab panels (vertical loads). The values considered for European space, Eurocode 3 should be used.
the loads (Table 6) are reference values. The situation
of distributed loading on the base structure was not 4.1. Classification of sections
simulated since it is already expected that the floor
For steel elements, Eurocode 3 Part 1-1 (2006)
grid elements behaves essentially as beams.
classifies the sections in order to take into account
After the numerical calculations, bending mo-
local buckling effect on the strength and capacity
ments, axial and shear forces were obtained for the rotation of the section (Class 1
4). According to
finite elements. As an example, Figure 6 presents the Clause 5.5 of Eurocode 3 Part 1-1 (2006), this
results for one load case. classification is based on the ratio between the length
The prevalent internal forces calculated for each and the thickness (c/t) of the fully or partially
component of the shipping containers are presented in compressed elements that compose sections (webs
Table 7. The nomenclature used for the forces is in and flanges), the internal forces of the section (axial
accordance with Eurocode 3 Part 1-3 (2004): axial force or bending moment) and the structural steel
forces (N, N or N ), shear forces (Vz and Vy) and class. The limit values of the c/t ratios are given in
bending moments (Mz and My). It was observed that, Table 5.2 of Eurocode 3 Part 1-1 (2006).
for the majority of the components, the most promi- Based on the results of the Section 3 (the
nent internal force is the axial force, eventually majority of the components of the containers were
6 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

subjected essentially to axial forces), the classification forces. Based on the simplification adopted in Section
of the sections was made considering that all the 4.1 (all the elements of the sections are in compres-
elements that compose the section are in compression sion), the calculation of the effective sections assumes
(situation less favorable for local buckling). It was that the section is composed by individual plates.
observed also that, except for elements BCM1, BCM3, The effective geometrical properties are calculated
BCM4, BSR, FS, FCP, DCP, and TSR for model by the usual methods, ignoring noneffective areas.
40’HC and for elements BCM1, BCR, FS, FH, FCP, After this, the safety verification of Class 4 sections
and DCP for model 20’HC, the remaining sections of subjected to normal stresses is made in the same
cold-formed profiles are classified as Class 4. Clause way as for Class 3 sections (Eurocode 3 Part 1-1
5.5.2 (2) of Eurocode 3 Part 1-1 (2006) states that for 2006).
these elements, the reduction in strength due to local According to Clause 4.4 of Eurocode 3 Part 1-5
buckling effect should be considered by the calcula- (2003), the effective area of a plate in compression,
tion of effective widths for elements that compose the Ac,eff, with area Ac, is given by:
section, according to Eurocode 3 Part 1-5 (2003) for
noncommercial sections (Johansson et al. 2001). For
Ac;eff ¼ qc  Ac ; (1)
commercial cold-formed sections, Eurocode 3 Part 1-3
(2004) should be used (Davies 2000; Rondal 2000).
where rc is a reduction factor for the plate buckling.
For internal elements (webs), rc is given by:
4.2. Calculation of the effective sections
The calculation of the effective sections depends on
the stress distribution, which depends on the internal qc ¼ 1 for kp  0:673; (2)

Table 3. Elements of the shipping container 40’HC

Designation /Illustration Transverse sections of the components

BCM1 BCM5 BCM4
Base structure

117.5
117.5

4 4 4
122

R4 R4
R4

45 45 45

BCM2 BCR BCM6

26
R4.5
32.5

4
150
R4.5 4.5
129
122

4.5
R4

45 30 80 R9

R9
4.5

BCM3
R4.5
154.5

FP

40 25 1029 25 40

few
18
2
45,6

Frontal face
R2

71 110 104 250 250 110 52

1019

FCP
FH
Journal of Civil Engineering and Management, 2013, iFirst: 1
19 7

Table 3. (Continued)

R8

87
R4

56
60

153
FS 56

R8
3 R3

6
60
60 12 174
R

Door face
56

12
R6
DCP

40
6

46
R1
230

2
R9

28
45

4
DS 4,5 DH 4
140

R4
5
4,
R

R8
110
65

Lateral face
TSR sw2´
3 R3
60

36

1,6

60 35 278 68 72 68 35

sw1/sw3
36

37 68 140 70 278 278 68 72 68 37

sw2
36

1,6

37 68 72 68 70 278 278 68 72 68 37

Roof roof

45.5 91 91 91 91 91 91 91 91 91 45.5
13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5
8 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

Table 4. Geometrical properties of the gross sections

Profile A (m2) Iy (m4) Iz (m4) Asy (m2) Asz (m2)

BCM1 7.95E
04 1.67E
06 1.44E
07 2.96E
04 4.24E
04

BCM2 9.15E
04 2.04E
06 4.00E
07 4.16E
04 4.24E
04
BCM340’HC 0.61E
03 0.29E
05 0.74E
06 3.69E
04 1.49E
04
BCM440’HC 7.89E
04 1.57E
06 1.43E
07 2.96E
04 4.06E
04
BCM540’HC 9.09E
04 1.90E
06 3.98E
07 4.16E
04 4.06E
04
BSR40’HC 1.13E
03 3.27E
06 5.29E
07 3.53E
04 5.56E
04
BSR20’HC 1.01E
03 3.31E
06 1.36E
07 1.94E
07 2.70E
04
BCM640’HC 1.75E
03 5.77E
06 3.28E
06 8.71E
04 6.59E
04
BFP40’HC 8.73E
04 2.08E
06 2.72E
07 2.23E
04 6.07E
04
DCP 3.81E
03 1.12E
06 1.80E
05 2.57E
03 7.02E
04
DH40’HC 2.55E
03 4.97E
06 2.02E
05 1.67E
03 8.08E
04
DH20’HC 2.57E
03 5.84E
06 3.02E
05 4.81E
06 1.53E
03
DS 1.70E
03 5.06E
06 4.47E
06 8.96E
04 6.52E
04
FCP 2.98E
03 1.28E
05 1.45E
05 1.35E
03 1.21E
03
FH40’HC 1.74E
03 1.73E
06 1.84E
05 1.36E
03 2.84E
04
FH20’HC 6.61E
04 3.51E
07 3.51E
07 0.00E 00 2.88E
04
FS40’HC 6.80E
04 3.66E
07 3.66E
07 2.88E
04 2.88E
04
FS20’HC 1.26E
03 3.59E
06 1.16E
06 7.42E
07 4.91E
04
TSR 6.80E
04 3.66E
07 3.66E
07 2.88E
04 2.88E
04
Sheet A (m2) Iy (m4) Iz (m4) e (m) l (m)
sw1/sw340’HC 2.36E
03 4.49E
07 2.45E
04 2.00E
03 1.116
sw120’HC 2.36E
03 4.49E
07 2.45E
04 2.00E
03 1.105
sw240’HC 1.89E
03 3.67E
07 1.96E
04 1.60E
03 1.116
sw220’HC 1.89E
03 3.67E
07 1.96E
04 1.60E
03 1.019
few 2.49E
03 9.44E
07 2.13E
04 2.00E
03 1.019

where c
ratio between maximum and minimum

kp  0:055ð3 þ wÞ stress in the plate (Tables 4.1 and 4.2 of Eurocode 3
qc ¼  1 for kp > 0:673;
k2p Part 1-5 (2003)); b
width of the plate, equal to the
ð3 þ wÞ  0: ð3Þ distance bp between points of adjacent vertices of
the element (Fig. 7); t
plate thickness; ks
plate
For external elements (flanges), rc is given by: buckling coefficient (Tables 4.3 and 4.4 of Eurocode 3
Part 1-5 (2003)); scr
critical elastic stress of the
qc ¼ 1 for kp  0:748; (4) plate, calculated by:
kp  0:188ð3 þ wÞ
qc ¼  1 for kp > 0:748: (5)  2
2 rcr ¼ kr  189; 800  t=b :
kp

The slenderness coefficient for one plate kp is In accordance with Clause 2.2 (5) of Eurocode 3
given by: Part 1-5 (2003), for a global analysis as the one carried
sffiffiffiffiffiffi
fy b=t
kp ¼ ¼ pffiffiffiffiffi ; (6)
rcr 28:4  e kr

Fig. 3. Definition of shear areas (section BCM1) Fig. 4. Modeling of the trapezoidal plate
Journal of Civil Engineering and Management, 2013, iFirst: 1
19 9

Table 5. Geometrical properties of strengthening bars

Sheet b (m) h (m) A (m2) Iy (m4) Asz (m2)

sw1/sw340’HC 1.69E
04 2.05E
01 3.46E
05 1.21E
07 2.88E
05

sw240’HC 1.38E
04 2.05E
01 2.83E
05 9.90E
08 2.36E
05
few40’HC 3.47E
04 2.07E
01 7.17E
05 2.56E
07 5.98E
05
sw120’HC 1.72E
04 2.03E
01 3.49E
05 1.20E
07 2.91E
05
sw220’HC 1.39E
04 2.04E
01 2.84E
05 9.84E
08 2.37E
05
Few20’HC 8.39E
04 1.58E
01 1.33E
04 2.78E
07 1.11E
04

out in Section 3, the reduction of the sections can be

Table 6. Load cases analyzed
neglected when the effective area of an element in
compression is greater than 50% of the gross area
(rc ] 0.5). Thus, it is necessary to check this
condition to know if the elastic analysis of the
containers performed in Section 3 (with gross area)
is valid or not. For this purpose, effective sections were
computed for all Class 4 elements (considering the
section in compression). Table 9 illustrates all the
calculated effective sections, so that a comparative
analysis can be carried out with Tables 2 and 3. It is
observed that for all elements, excepted FP element,
the reduction of the area is lesser than 50% of the
gross area. Therefore, it can be considered that the
global results of Section 3 remain valid. New geome-
trical properties for the effective sections were com-
puted to be used to check for safety design (Table 8).

5. Case study
This section presents a real case study based on a
single-family house for which a structural solution
based on refurbished shipping containers (20’HC and
40’HC) was studied.

5.1. Architecture
Figures 8
11 present some architectural drawings of
the building.

The building with two floors has an area of 115 m2

at Floor 0 and 82 m2 at Floor 1. This last one is partially
suspended. The ceiling height is 2.54 m on both floors.

5.2. Structural conception

After the study of some configurations, the chosen
Fig. 5. Numerical model of the shipping containers solution is composed with 10 shipping containers,
10 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

Table 7. Preponderant internal forces

Element Internal forces Element Internal forces

DS N; Vy; Vz; My; Mz BCM1 N; Vz; My

DCP N; Vy; Vz; My; Mz BCM2 N; Vz; My
DH40’HC N BCM3 N; Vz; My
DH20’HC N; Vy; Vz; My; Mz BCM4 N; Vz; My
FH40’HC N; Vz; My BCM5 N; Vz; My
FH20’HC N BCM6 N; Fz; My
FS40’HC N FP N-; Vz; My
TSR20’HC N; Vz; My Few N; Vz; My Fig. 7. Width of the plate
TSR40’HC N; Vz; My sw40’HC
1/3 N
FS20’HC N; Vz; My sw20’HC
1/3 N of the containers, continuously connected to the
FCP N; Vy; Vz; My; Mz sw40’HC
2 N containers by welding. These trusses are supported
BSR40’HC N; Vz; My sw20’HC
2 N by steel columns with soil foundations (Fig. 13). The
BSR20’HC N; Vz; My
geometry of the lateral trusses was defined taking into
account esthetic aspects as well as the constraints of
5 models 20’HC and 5 models 40’HC (Figs 12 and 13). architectural design, namely the location and the
It should be pointed that the architecture had to be dimensions of the openings. RHSH profiles (Class
optimized to allow the full utilization of the containers S355) were used to compose external trusses and steel
areas. columns.
In a preliminary study phase it was verified that Structural coverage for flat floors is executed by
the suspension of the containers in the Floor 1 was not using adapted base structures of additional 20’HC
compatible with their resistance because of the open- containers. For Floor 1, the base structures were
ings in the walls. This problem was solved by using placed on the perpendicular direction and suported
two external and lateral trusses along the entire length on the upper strings of the trusses (Fig. 14).

Fig. 6. Results obtained for load case 2 (model 40’HC)

Journal of Civil Engineering and Management, 2013, iFirst: 1
19 11

Table 8. Geometrical properties (effective sections)

Profiles A (mm2) Iy (mm4) Iz (mm4) Asy (mm2) Asz (mm2) Wel.y (mm3) Wel.z (mm3)

DS 1.68E
3 4.83E
6 4.46E
6 8.70E
4 6.52E
4 5.22E
5 3.82E
5

DH40’HC 1.96E
3 3.99E
6 4.85E
6 1.08E
3 8.08E
4 6.19E
5 4.66E
5
DH20’HC 1.89E
3 4.85E
6 4.31E
6 8.37E
4 9.16E
4 6.85E
5 4.43E
5
FH40’HC 7.58E
4 9.20E
7 4.69E
7 3.99E
4 2.84E
4 2.01 E
5 8.09E
6
BCM2 8.38E
4 1.81E
6 2.04E
7 3.37E
4 4.24E
4 2.83E
5 4.83E
6
BCM5 8.19E
4 1.65E
6 2.01E
7 3.37E
4 4.06E
4 2.69E
5 4.80E
6
BCM6 1.64E
3 5.03E
6 3.14E
6 7.88E
4 6.59E
4 5.49E
5 3.02E
5
FP 2.47E
1 9.14E
6 6.86E
5 5.92E
4 8.48E
4 9.90E
5 1.19E
3
Few 1.92E
3 6.74E
7 1.53E
5

2.89E
5 3.22E
4
sw40’HC
1/3 2.13E
3 4.19E
7 2.15E
5

2.36E
5 3.93E
4
sw20’HC
1/3 2.20E
3 4.37E
7 2.19E
5

2.34E
5 3.95E
4
sw40’HC
2 1.40E
3 2.85E
7 1.43E
5

1.68E
5 2.63E
4
sw20’HC
2 1.47E
3 3.06E
7 1.46E
5

1.68E
5 2.70E
4

Table 9. Effective sections

121 R9 R6.75
101 101
28

45 R4.5
140

4.5

154.5
R4.5 fp
DS
4.5

4.5
49.03

49.03
54.41
25.44 25.44
176.17
40 1049 40
4 58.17
951.08

DH 40’ 37.72 37.72

109

4 28.32
R4
HC 2

110 R8
17.67 38.01 38.01
few
162.78
44.78
33.12 33.12
3 26
28

33.33 33.33
4
138

34.14 34.14
DH 20’
R4
HC 34.14 34.14
SW13 40’HC
R8
110
26.35 33.12
111.63
33.33 33.33 24.68
4

59.22 R8
34.14
34.14
87

FH 40’ SW13 20’HC

R4 34.14
HC 34.14

48.9
R8 51.59 R8 21.57 22.1

51.59 28.8728.87
BCM2 BCM5 29.4
117.5

4
R4 R4
29.4 29.4 SW2 40’HC
122
4 45

21.3 28.7228.72
100
45 28.87 28.87
45 29.4
29.4

R4.5 150 29.4 SW2 20’HC

32.5

4.5 29.4
BCM6
57.39

R9
12 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

Fig. 8. Single family house: lateral views

Fig. 9. Single family house: Floor 0

Fig. 10. Single family house: Floor 1

Journal of Civil Engineering and Management, 2013, iFirst: 1
19 13

Fig. 11. Single family house: Section B-B

Fig. 12. Configuration: Floor 0

Fig. 13. Configuration with external trusses: Floor 1

14 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

lose some of its original strength. Therefore, vertical

strengthening elements near to the openings (both
sides) were added (Figs 15 and 16). TPS profiles were
used for the strengthening elements. For one opening,
the total area of the strengthening elements is equal to
the area of the removed sheet/profile.
The project drawings for the refurbishment and
preparation for the steel work warehouses are im-
portant in order to ensure no problems on construc-
tion place during the assembly of the containers. Such
drawings, with full details, should clearly indicate the
location and the dimensions of the openings, as well as
the location and connection of the strengthening
elements. Figures 15 and 16 present preparation
drawings for some containers.
Fig. 14. Adaptation of base structures for the roofs
5.4. Assembly of the containers
A reinforced concrete raft foundation was Figure 17 illustrates an overview of the containers
adopted to found containers and strengthening pro- after assembly (external trusses are not illustrated).
files. The containers are joined together by welding
between some profiles and corner pieces. Figure 18
5.3. Refurbishment and preparation of containers presents some details of welded connections, namely the
section C-C on Floor 1 (Fig. 13) to show the connection
The remodeling process of shipping containers is between the containers and the external trusses.
initiated by removing the doors as well as replacing
original plywood floor. Next, the openings are made
5.5. Numerical model
by cutting steel wall sheets and profiles in accordance
with architectural requirements (some examples are To evaluate the internal forces in containers elements,
presented in Table 10). With this procedure, containers a numerical model (based on the assumptions of

Fig. 15. Preparation of the container 1-40’HC.1

Fig. 16. Preparation of the container 6-20’HC.3

Journal of Civil Engineering and Management, 2013, iFirst: 1
19 15

Table 10. Refurbishment of containers

Fig. 17. Assembly of containers (overview)

Section 3) was implemented with finite elements

analysis software (LUSAS) (Fig. 19). Such a model
includes the openings, the strengthening profiles, and
the external trusses. The containers at Floor 0 are
simply supported at the lower corner pieces (all
translations restrained).
The geometrical properties of container elements
were calculated based on gross sections (Tables 4 and 5).
For FP profile, the effective section area is less than 50%
of gross section area (Section 4.2), so effective geome-
trical properties were considered (Table 8). For the
strengthening elements (TPS profiles) and external

Fig. 18. Welding connections (transversal sections)

16 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

“ cladding siding external walls: 5.4 kN/m;

“ floor and roof coat: 1.0 kN/m2.
Variables loads (characteristic values):
2
“ live load on roofs (terrace): 2.0 kN/m (ci 0);
2
“ live load on floors: 2.0 kN/m (c0 0.4; c1 
0.3; c2 0.2);
2
“ snow: 1.7 kN/m (c0 0.6; c1 0.3; c2 0);
“ earthquake: based on a dynamic analysis with
response spectrum seismic loading (ci 0) (Chu
et al. 2011).
To check safety for the ULS, fundamental and
seismic combination of actions were applied (Euro-
code 2001). To check the deformation for the SLS,
quasi-permanent combination of actions was used
Fig. 19. Overview of the global numerical model (Eurocode 2001).

trusses elements (RHSH profiles), the chosen commer- 5.7. Criteria’s for ultimate limit states
cial section was based on pre-design simplified models.
To check safety of cold-formed steel profiles, Euro-
code 3 Part 1-3 (2004) was used. For commercial hot-
5.6. Actions rolled steel profiles, procedures of Eurocode 3 Part 1-1
The design actions to check the safety of the structural (2006) were used.
elements were: The following ultimate limit states were checked:
tension force, compression force, bending moment,
Dead loads (average values): shear force, compound bending, interaction between
3
“ own-weight of structural steel: 7850 kN/m ; internal forces, and resistance to lateral buckling.
3
“ own-weight of plywood: 0.70 g/cm ; To check the safety of the sections for the
2
“ equivalent own-weight of partitions: 1.1 kN/m ; bending moments (Ultimate Limit State), additional

Table 11. Design strengths for profiles (gross sections)

Profile NRd (kN) MRd.y (KN m) MRd.z (KN m) Vw.Rd.z (kN) Vb.Rd.z (kN) Vw.Rd.y (kN) Vb.Rd.y (kN)

DCP 1188.8 14.98 36.98 73.79 59.10 429.71

FH20’HC 206.06 3.65 3.65 52.09 46.00


FS40’HC 206.06 3.65 3.65 52.09 34.30


TSR20’HC 206.06 3.65 3.65 52.09 56.00


TSR40’HC 206.06 3.65 3.65 52.09 56.00


FS20’HC 393.76 12.38 4.57 41.23 41.00 37.62 32.50
FCP 929.25 27.51 29.75 196.41 126.00 222.45 193.00
BSR40’HC 342.95 11.21 2.66 111.50 113.80


BSR20’HC 316.00 11.83 1.07 117.19 104.25


BCM1 248.02 8.55 1.33 76.68 70.67


BCM3 242.41 0.46 4.64




BCM4 191.12 8.11 1.32 73.43 74.20

Table 12. Design strengths for profiles (effective sections)

Mc.Rd.y Mc.Rd.z Vw.Rd.y

Profile Nt.Rd (kN) Nc.Rd (kN) (kN m) (kN m) eNy (mm) eNz (mm) Vw.Rd.z (kN) Vb.Rd.z (kN) (kN) Vb.Rd.y (kN)

DS 531.4 522.5 16.27 11.93 0.2 1.5 118.0 92.5 157.5 140
DH40’HC 795.6 612.4 19.29 14.52 40.9 10.7 146.1 90.3 147.6 0
DH20’HC 802.4 587.1 21.36 13.82 57.0 11.9 147.6 136.0 172.9 127
FH40’HC 537.4 236.3 6.27 2.52 94.1 20.6 51.4 60.0 72.1 46.3
BCM2 285.4 260.9 8.83 1.51 4.5 4.8 76.7 113.0


BCM5 279.8 255.3 8.37 1.50 4.5 4.7 73.4



BCM6 536.6 510.8 17.11 9.41 1.4 4.3 119.2 99.0


FP 995.5 414.4 15.44 184.7

153.4 93.0


Journal of Civil Engineering and Management, 2013, iFirst: 1
19 17

Table 13. Design strengths for sheets

Sheet Nt.Rd (kN/m) Nc.Rd (kN/m) MRd.z (kN m/m) Vw.Rd (kN/m) Vb.Rd (kN/m)

Few 761.79 588.32 98.55 61.62 60.66

sw1/340’HC 659.52 594.35



sw1/320’HC 659.88 622.01



sw240’HC 528.26 391.12



sw220’HC 528.42 411.87

moments were added due to the eccentricity of the 5.8. Design resistances and safety verification
barycentre due to the reduction of the section in order
This section summarizes the verifications carried out
to take into account for local buckling, as specified in only for the elements that compose the containers. For
Eurocode 3 (2004). the strengthening profiles and for the profiles that
To check the resistance to lateral buckling, it is compose external trusses, being current commercial
necessary to compute the resistance to buckling sections the verification was based on Eurocode 3 Part
(bending moment): Mb,Rd. This resistance depends 1-1 (2006). Such verifications are not summarized here.
on the elastic critical moment for lateral buckling, Table 11 summarizes the values for the design
which in turn depends on unknown parameters for strengths of the profiles based on gross section
many of the noncommercial sections under analysis. (profiles for which effective section was not calcu-
In fact some of these parameters, such as warping lated). Table 12 summarizes the values for the design
inertia, are obtained from experimental studies. Then, strengths of the profiles based on effective section.
it is not easy to check buckling for many profiles being Table 13 summarizes the values for the design
in study. In accordance with Clause 6.3.2.1 (2) of strengths of sheets. The front face sheets present
Eurocode 3 Part 1-1 (2006), profiles with sufficient bending moment around z and axial force. The other
lateral bracing are not susceptible to lateral buckling. sheets present essentially axial force.
Thus, to overcome the problem mentioned above, From a comparative analysis between design
profiles should be braced in order that buckling internal forces for the several combinations (the
verification do not need to be carried out. In fact, several quantity of values are not presented here)
for many elements such condition is already satisfied and design strengths on the critical sections of the
due to the connection to other elements. elements that compose the containers, it was possible
to list several elements that did not verify safety (Table 14).
The problems are mainly associated with compound-
bending verification. Thus, it was necessary to provide
additional strengthening elements (RHSH profiles) to
Table 14. Profiles with insufficient resistance solve these problems.

Profile Localization Conclusions

20’HC
TSR 6-20’HC.3 The transposition of code procedures suited for
TSR40’HC 1-40’HC.1 current steel building structures to verify the safety
2-40’HC.2 of the elements that compose the shipping containers
2-40’HC.2
is possible, but some verifications are not easily carried
3-40’HC.3
3-40’HC.3
out due to the lack of some important geometrical
FCP 1-40’HC.1 properties (for instance, buckling verification). This
2-40’HC.2 problem appears because it is necessary to analyze
BCM6 2-20’HC.2 noncommercial cold-formed steel profiles which are
BSR40’HC 3-40’HC.3 not parameterized for the application of code proce-
1-40’HC.1 dures. The application of the structural codes for this
1-40’HC.1 constructive system requires the assumption of several
2-40’HC.2 simplifications for the calculation model and for the
3-40’HC.3 verifications, and also the adoption of construction
2-40’HC.2 details in order to impose a behavior to the compo-
BSR20’HC 6-20’HC.3
nents to bring them closer to the assumed simplified
5-20’HC.2
4-20’HC.1
calculation model.
8-20’HC.5 Moreover, the shipping containers are composed
of several steel elements. The majority of the non-
18 L. F. A. Bernardo et al. Use of refurbished shipping containers for the construction of housing buildings

commercial sections are classified as Class 4. For these ISBU (Intermodal Steel Building Units and Containers
elements, effective sections must be computed to take Homes). 2009. ISO shipping container specifications/
into account the effect of local buckling. The calcula- materials. Cheyenne, WY: ISBU Association.
ISO 1496-1:1990. Series 1
container shipping. Specifi-
tion of the geometrical properties of these sections is a
cation and testing
part 1: containers for marine
lengthy and complex process. applications in use. Geneva, Switzerland: International
This study shows that the calculation of struc- Organization for Standardization. 24 p.
tural projects with this construction system by using ISO 668:1995. Series 1
container shipping. Classification,
the resources currently available for the structural dimensions and calculations. Geneva, Switzerland:
engineer (structural codes) is not easy. The required International Organization for Standardization. 6 p.
calculations, the lack of tabulated values for the ISO 3874:1997. Series 1
container shipping. Handling and
safety. Geneva, Switzerland: International Organiza-
geometrical characteristics of the noncommercial steel
tion for Standardization. 29 p.
profiles that compose the shipping containers and the
ISO 830:1999. Freight containers
vocabulary. Geneva,
lack of experience about the structural global and Switzerland: International Organization for Standar-
local behavior of shipping containers are some dization. 40 p.
negative aspects to have into account. Moreover, it Johansson, B.; Maquoi, R.; Sedlacek, G. 2001. New design
should be noted that there are several shipping rules for plated structures in Eurocode 3, Journal of
containers models on the market. Constructional Steel Research 57(3): 279
311. http://
Nevertheless, this study shows that the feasibility dx.doi.org/10.1016/S0143-974X(00)00020-1
Lun, Y. H. V. 2011. Green management practices and firm
of this construction system, based on the use of
performance: a case of container terminal, Resources,
refurbished shipping containers as construction mod- Conservation and Recycling 55(6): 559
566. http://dx.
ules for buildings, should be recognized. doi.org/10.1016/j.resconrec.2010.12.001
LUSAS. 2010. Lusas finite element system, version 14.3.
References Kingston-upon-Thames, England: FEA
Finite Ele-
ment Analysis Ltd.
Chu, Y.-P.; Yao, Y.; Deng, Y.-J. 2011. Seismic behavior
Murdock, J. 2009. Now shipping to a site near you: cargo
analysis on the cold-formed in modular house,
container offices, Architectural Record 197(10): 34.
Advanced Materials Research 150
151: 512
516.
Nunes, N. C. G. 2009. Exploitation of shipping containers for
http://dx.doi.org/10.4028/www.scientific.net/AMR.225-
housing. Master Thesis. University of Beira Interior,
226.512
Portugal (in Portuguese).
Davies, J. M. 2000. Recent research advances in cold-formed
Pisinger, D. 2002. Heuristics for the container loading
steel structure, Journal of Constructional Steel
problem, European Journal of Operational Research
Research 55(1
3): 267
288. http://dx.doi.org/10.1016/ 141(2): 382
392. http://dx.doi.org/10.1016/S0377-2217
S0143-974X(99)00089-9 (02)00132-7
Eurocode. 2001. Basis of structural design. Brussels: CEN - Rondal, J. 2000. Cold-formed steel members and structures:
European Committee of Standardization. 88 p. general report, Journal of Constructional Steel Research
Eurocode 3. 2003. Design of steel structures. Part 1-5: plated 55(1
3): 155
158. http://dx.doi.org/10.1016/S0143-
structural elements. Brussels: CEN - European Com- 974X(99)00083-8
mittee of Standardization. 53 p. Vijayalaxmi, J. 2010. Towards sustainable architecture
a
Eurocode 3. 2004. Design of steel structures. Part 1-3: case with Greentainer, Local Environment: The Inter-
general rules. Supplementary rules for cold-formed national Journal of Justice 15(3): 245
259. http://dx.
members and sheeting. Brussels: CEN - European doi.org/10.1080/13549830903575596
Committee of Standardization. 125 p. Webb, M. 2006. Container art: Shigeru Ban’s inventive yet
Eurocode 3. 2006. Design of steel structures. Part 1-1: frugal nomadic museum berths on the Santa Monica
general rules and rules for buildings. Brussels: CEN - Beachfront, Architectural Review 219(1311): 48
53.
European Committee of Standardization. 116 p.

Luı́s F. A. BERNARDO. Assistant Professor at the Department of Civil Engineering and Architecture of the
University of Beira Interior, Portugal. He is a member of the research Centre C-made: Centre of Materials and
Building Technologies, Portugal. His research interests include the mechanical behavior of structural concrete and
the development of new structural materials and building systems.
Luiz A. P. de OLIVEIRA. Associate Professor at the Department of Civil Engineering and Architecture of the
University of Beira Interior, Portugal. He is a member of the research Centre C-made: Centre of Materials and
Building Technologies, Portugal. He is a member of CIB-W115 Commission, Construction Materials Stewardship.
His research interests include the technology of concrete and masonry structures, particularly the composites
rheological behavior and hi-value wastes materials and components.
Miguel C. S. NEPOMUCENO. Assistant Professor in Construction at the Department of Civil Engineering and
Architecture of the University of Beira Interior, Portugal. He is a member of the research Centre C-made: Centre of
 Journal of Civil Engineering and Management, 2013, iFirst: 1
19 19

Materials and Building Technologies, Portugal. His research interests include the construction materials, particularly
the cement based materials. His research interest includes also building physics, indoor environment and building
systems.
Jorge M. A. ANDRADE. Assistant Professor at the Department of Civil Engineering and Architecture of the
University of Beira Interior, Portugal. He is a member of the research Centre C-made: Centre of Materials and
Building Technologies, Portugal. His research interests include the behavior of steel, aluminum, and reinforced
concrete structural elements, mainly numerical simulations of problems.

View publication stats