Tempory pedestrian door for shipping container

[hotponyshoes]

I've been asked to put a pedestrian (easy access) door into a shipping container.

Not a problem in itself, I've done a few before.

But, the guy only wants to use it as temporary storage then resell it so he's asking about being able to revert the shipping container to it's previous condition once he has finished with it.

All I can think of so far is to, remove one of the existing doors, fit an infill panel, fit a door into the panel.

I might try and talk him into just having a door fitted into the existing door.
I doubt he'll be reselling it to the shipping industry so might even make it easier to sell when the time comes?

Unless anyone has any better solutions?

 

[gaz1]

for the side panels

only way i can see it being done is by using the bolt through door jambs fixed to angle iron to create the door frame

then when the door is cut out you can keep the cut out panel and reweld the panel back on to the container when the door frame is removed again

other way is remove one of the container doors

make a new container door and make sure it can be locked solid and make a manhole door access for it

as some containers have dual bar locks or a single bar lock

 

[bricol]

I think your door replacement panel is the easiest - other than getting the original door off and then back on - I suspect it's not a one man, balancing it on one foot, sort of a job. Unless the door can simply be left propped open to give the opening for the infill?

Remove the existing locking bars on one door, and fitted a more conventional handle/latch for easier use? Even perhaps removing one of the existing locking bars so only one has to be juggled to shut it?

 

[Nomad]

I think your door replacement panel is the easiest ... Unless the door can simply be left propped open to give the opening for the infill?

I've been looking at doing something similar for myself to create storage and temporary accommodation.
Leaving one door open (as shelter / windbreak) and fitting an infill with a with pedestrian sized opening door would be my choice.

A lot depends where's located, in the corner of a secure yard a permanently open door won't be an issue, neither will slightly reduced security.
If it's parked on a deserted patch of land in the middle of nowhere you need all the security you can get.

 

[Agroshield]

...when the door is cut out you can keep the cut out panel and reweld the panel back on to the container...

AIUI, most containers are made from Corten steel. I do not know what implications that has for the welding before sale (whether the welds will have the same rust resistance as the surrounding material).

You'd need to fill 2 x whatever width of cutting disk you use with the welds. There is no easy kerf-less cut possible.

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Trapdoor in the floor and Tom, Dick or Harry. Plywood is easy to replace.

 

[More Amps]

One solution might be to construct an inner timber door frame across the width of the container set back from the doors. If he needs security, then lock the outer doors and when it comes to selling on, all he has to do is remover the inner frame. Picture below as I'm bored...

 

[Kram]

Thats a neater solution if space allows it.

You'd need to fill 2 x whatever width of cutting disk you use with the welds. There is no easy kerf-less cut possible.

With 0.8mm discs thats not a huge problem, end up about 1mm gap each side.

I cant remember what shipping containers are like, but surely, cut a door hole with grinder, weld the same peice back in, job done.

Or does he want you to construct a new panel, such that at resale time, he can do the swap without assistance?

 

[hotponyshoes]

I've cut them before using a slim disc without a problem. Because you are always cutting on the vertical I've never spent much time marking out or cutting carefully.
With a bit of effort I'm sure I could cut out a piece with a 1mm kerf that would drop back into place well enough.
They are usually corten, I have got corten tig rods and presumably corten mig wire is easily available.

But, they are all corrugated sheet, much like roofing sheets. When I have done them before I've just welded in an angle iron frame and used bits of flat bar to fill in any gaps left by the valleys then smothered the lot in seam sealer.

I've always fitted the angle facing outwards, over the existing panel and stitch welded into place. I suppose I could cut a bigger hole and fit a frame within it.

It would most likely be me who has to 'restore' the containers when he's done with them.
He'll only be selling them on for storage so I don't think they'll need corten wire and any sort of certification but I'd want to find matching paint at least.
I'd also have concerns about the amount/length of welding, and preventing distortion.

Security is not really an issue, these are only going in temporary as work units to enable the farmer to get some sort of grant for a proper building!

I did think about just making the existing door(s) easier to open. You would want some method of doing it one-handed. You could just remove one of the closure bars.
Closing them is an issue though, I'm not weak and I need both hands to close one. Mainly because you have to pull both bars together to gradually compress the rubber door seal. Might be worth looking to see if the door seal can be easily removed then some sort of guttering/weather strip fitted to keep it dry?
The doors are still big and heavy though!
Maybe spring assist or counterweight but I can't think of anything that will work in both directions..

The 'doors open' idea might well be easiest, I've not seen the actual containers yet (he's not bought them yet) but I've seen plenty that have bars just inside the doors for Load lashing. Might well be easier to follow MoreAmps drawing above and make up a frame that can be clamped onto those bars with u-bolts or something. Fit a bulkhead with door to that.

Original doors could then be left open and maybe some sort of 'roof put across the top to both hold the doors in place and provide a sort of porch?

Only concern with the doors being left open is that the inside of the doors (and the rest of the container) are usually just finished in primer. (I think, maybe its actually paint that looks like primer)
Don't know how they would stand up being exposed to the weather?
If I could identify the primer/paint it wouldn't take much to re-coat them if required in 6mths time but I wouldn't want to be repainting the whole inside if I couldn't get a paint match!

 

[hotponyshoes]

Not sure how easy it is to remove a door either?
The manoeuvre of it is not a problem but I have never noticed any bolts on the hinges?
I'll have a proper look at one over the weekend..

 

[LiftedDisco]

If you are installing internal doors on a stud wall, simply weld some angle (tabs would do) to the inner face, then secure the studwork to the angle tabs and face the whole lot with board, composite panel etc to form the internal wall with door assembly.

Oh… if anyone (ie the potential end-user client) needs any 10’ containers, I have five that may well be available. One use containers in ‘as new’ condition - currently just to the south of Birmingham…

 

[gaz1]

with 2"-3" angle iron door frame on the outside all you would need is bolt holes drilled through and another piece inside to go through and bolt the door tight to the frame no welding needed to the container

sicka flex seal and thats it

 

[J1nx]

I’d convince him to have it done permanently, likely worth it in resell, I’ve bought ones done from Eagle plant and it’s well worth the premium imo.

 

[anto44]

I think this guy might be underestimating the cost here. Cutting a door into the side and then removing and putting back to standard again is a decent size job. A new 40' shipping container in Northern Ireland costs £4500 + vat, second hand ones are less than 2k. A well done side door won't devalue a second hand container, I'd tell him to do the door properly and use it as feature when selling.

 

[Maker]

One solution might be to construct an inner timber door frame across the width of the container set back from the doors. If he needs security, then lock the outer doors and when it comes to selling on, all he has to do is remover the inner frame. Picture below as I'm bored...

View attachment 468564

That's how our paint stores at work are constructed.