transform these “steel boxes” into something more than just a container.

Housing has always been a vital issue in how we provide shelter for our families and ourselves. While panelized buildings and the modular building industry have tried to reinvent and redefine the traditional “stick-built” construction method, they fall short in that they rely on nonstandard transportation sizes and the use of cranes in their erection. They are further complicated by the need for a traditional concrete foundation system and the inability to be quickly sent to a disaster site to replace destroyed housing. Their main advantage is the ability to be largely pre-assembled in a controlled environment by skilled craftsman.

Getting back to the surplus shipping containers, imagine if these could be put to use in the housing market. Previous attempts have had limited success in that the container itself was used as living space. While providing minimal headroom, the containers do not provide large enough spaces to be considered quality residential architecture. They also lack the ability to easily add electrical, mechanical, and plumbing systems without further modifications that reduce available space. My idea is different from these previous approaches in that I would use the containers as a building platform to erect a house with most systems already pre-assembled within the containers. The containers would in fact become the foundation / basement of the house while at the same time be the box that the house components are shipped in!

Just as nature creates the seed to allow a plant to grow in a new location, these containers can contain all the required components to erect a new residence for us to inhabit! The design challenge is to design a structure that can completely be contained and thus safely transported anywhere a typical truck can go. Once arrived at a proposed site, the containers should be able to be dropped into place and linked together to form a perfectly square and level building platform.

To demonstrate how this idea could work, I chose to use three standard 40-foot long containers, which are the most plentiful and typical. By placing three of these units together, we will create a building platform of 24 feet by 40 feet. A site would be prepared with either the container placed on piers to be above flood levels or more typically, buried below ground to be below frost level or place on grade using a frost protected shallow foundation system. The containers would be coated with a waterproofing barrier and placed on a drainage plane and insulation panels. Depending on local ground conditions, concrete footings may be completely avoided, as the entire frame will act to support the weight of the structure above. The boxes would be joined together to be a single structural unit with openings precut as needed prior to shipment. Once in place, the containers would be checked for Watertightness and insulation boards and a mat drainage system placed around them and backfilled.

Once set and leveled, the containers would form a perfectly square support frame for the building structure to be erected. Threaded studs would secure a timber frame structure that could be made from engineered lumber. Engineered lumber is stronger than dimensional lumber and comes from second growth, scrap, or recycled wood. Structural insulated panels would then be attached to this frame to form a continuous and highly insulated envelope. These panels sandwich between oriented strand particleboard, Polyicynene insulation, a low density, open-cell flexible expanding foam would provide a complete air barrier. Polyicynene is a completely water-blown, two component system in the polyurethane family. High efficiency doors and windows would complete the exterior building envelope. The exterior walls and roof could then be clad with any traditional finish. Exterior walls could be wood, vinyl, or fiber-cement panels. Roofing could be metal, asphalt shingles, or simulated slate panels.

Since the main floor is the top of the containers, only insulation panels need to be laid down which could be pre-grooved for running radiant floor heating pipe and electrical wires. Over this a laminate floor can be installed. The second floor loft can be a typical floor deck system. Mechanical and plumbing systems will be installed and connected to stubs and connections that were assembled in the container units. High efficiency appliances and mechanical equipment will ensure climate control and provide normal all house functions for this home.

The proposed floor plan is a typical open plan with two bathrooms and two with the possibility of three bedrooms. It features a two-story living and dining room with vaulted ceilings on second floor. Designed to be bright and spacious, the plan has 960 square feet on the first floor with 540 square feet on the second for a total of 1,500 square feet.

The floor plan had been designed based on the principals of universal design. All doors are three foot wide with adequate room for a wheelchair to maneuver. A residential elevator is a central feature and allows access to all levels. Such planning allows an owner to age in place without worry over future accessibility issues. Placing the basement on grade would allow easy access to the lift at this level.

A central idea for the house would be for it to be designed to withstand the forces of nature. Why is it that buildings defy “Moore’s Law”? I would submit that instead of home construction getting cheaper over time, it has gotten costlier, without getting more reliable. By getting back to the basics of “Shelter” we can revolutionize the building industry.

With some effort it is conceivable to design this building to be carbon neutral, in that it will not require any fossil fuels to operate. Since in total, the architectural sector controls a whopping 48 percent of total U.S. energy consumption and 46 percent of the total carbon dioxide production, any effort to limit the carbon footprint of a building can have profound impact if it can become the norm. Careful selection of individual components can maximize this effect. If such a home can be “off the grid”, the possibilies that such homes can be located in remote non-agracultural areas are much greater.

By conceiving of the entire house as a single unit, it is possible to design all building systems to work together for maximum benefit. It would be possible to provide a whole-house warranty similar to the “bumper to bumper” warrenties offered by car manufacturers. With an eye toward storm survivablity, the structure should out perform a typical house structure and already comes with a heavy steel storm shelter for a basement.

A simple business plan to move this idea forward is to initially build a single prototype demonstration unit on a site that has already been secured by the author. The proposed site is in the Town of Richland, NY, near the shore of Lake Ontario. Near Pulaski, NY, the site lies in the Snowbelt, which is characterized by heavy amounts of lake effect snow. It has a regional reputation for its heavy snow accumulations and for the long duration of winter conditions. A good test site.

The budget for the design and construction of the initial house unit and testing is $100,000. Once a house has been successfully constructed and tested, popularity of the concept will establish a backlog of orders. Once enough orders are received, a breeder facility will be secured as a warehouse and factory floor. This facility will modify the container units, fabricate and pack the house components. Depending on the number of units to be produced, the unit cost will be established. The cost should be below the market cost of a typical stick built house of the same size to make this commercial viable. In addition, the speed of erection, durability, and sustainability of the concept should make this an attractive option for the future homebuyer.

Long-term goals would be to locate breeder facilities throughout the world and provide multiple regional designs so that this concept will be replace over time the way we provide housing. The design of these homes should embrace the concepts of Sustainability, Durability, and Survivability. In short, these homes will be a sign of hope for our collective future.