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Converting Steel Shipping Containers to Housing

Bob talks about the vast number of steel shipping containers abandoned in America's ports. Because America is no longer an exporting nation, only an importing nation, it is too expensive to return the 700,000 containers clogging American ports. Tampa Armature Works (TAW) converts these containers to intermodal steel building units (ISBU's) for use by the military and as durable, affordable installations throughout the world. David Cross of TAW explains how they have developed a skeletal frame system that brings the container down to its most elemental structural elements from which anything can be built. Cross shows Bob "the world's largest toolbox," which is an ISBU converted into a series of bins, cargo holds, and roll doors that can organize, store, and protect all kinds of tools, gear, and equipment in a military setting. Once modified, these containers are perfect as storm-ready housing units, or "container homes", with corrugated sides, a bottom steel channel and flat-bar toprail functioning together like a steel I-beam. Inside, 1 1/8-inch marine-grade Apitone flooring is a huge and standard benefit in every ISBU. TAW can cut the openings for doors and windows, finish the exterior with heavy gauge steel, wrap it in a sheet-metal skin, spray it with SuperTherm insulative ceramic coating, and deliver it for $40 to $45 per square foot. The foundation and roof are then supplied on site by the contractor. With 17 million of these containers in circulation world-wide, this is a salvage, recycling, and green business initiative that can create heavy-gauge steel, hurricane-resistant housing fast and for about the same dollars as a light-gauge steel home. Cross and TAW are just looking for consumers willing to jump on board with the technology and opportunities ISBU's present.
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Converting Steel Shipping Containers to Housing

  computer-generated transcript - may not be 100% accurate

" If you've ever visited a major port like Charleston Miami or new York New Jersey you know that shipping containers are the standard method of moving goods around the world. Because the US is no longer a manufacturing nation, we don't have many goods to export. But we're real good at buying foreign goods so we end up with a lot of empty containers and it doesn't make economic sense to ship them back empty. There are 700,000 of these containers just abandoned in US ports. Here at Tampa Armature Works a team of engineers and shipping experts have been converting what are basically really sturdy steel boxes into what they call intermodal steel building units or ISBUs to be used for military contracts and used in operations around the world. Given the urgent need for affordable and storm resistant housing that can be built in a hurry in places hard hit by hurricanes and earthquakes it makes a lot of sense to find a way to adapt ISBUs be used for residential use."

" Well TAW has been working on a skeletal frame system a system that allows us to take an intermodal cargo container down to its most - its barest element components. And it's done through a series of intermediate posts. And from that we can build just about anything. Here we have what we call the world's largest toolbox. And yes it has some fold up awnings. Some fold down awnings. us. Some roll up. Doors. And an inside. This particular unit has a cargo handling system that allows the military to go to door two container 123456. 123456 and number bin number or three and find whatever it is they're looking for for their particular project. For shipping cargo container is designed and built. built built to cargoes around move cargoes world interchange interchanging cargoes out from one port to another. And I An an ISBU ISBU, ISBU is steel building unit unit, that cargo container has been changed and modified to become a housing system. So to suit the customer's application this particular particular know. unit needs be unit needed to to shortened up feet feet. What's on What's going here is the use of a you some plasma torch gives us a very clean cut other than little grinding we're ready to weld once we take -- this end off. in In conversion In the container into -- an ISBU, view an intermodal steel building unit. unit, what have here is a nine foot six inch tall I beam which is created. By this created by you see down here. This corrugated web. Of metal web of all the way up to this flat bar top -- that is rail effect a large I mean. We lose beam. integrity when we cut out this window aperture that you note up here and so bringing back. This channel back this that lost structural integrity."

" These units comes with a Marine grade apatone -- flooring. Its an inch and an eighth thick, to make you sick it's of many laminations nations and it's just it's a feature that's with the ISBU containers that we couldn't build into them. It's already there."

" So the floor is wood but basically the container is one big steel box and isn't gonna be murder living in a steel box in the Florida sun. One would think sir but this particular unit this house system will be coated with supertherm ceramic insulative -- paint. This coating is gaining great popularity in Europe in the and the Far East. And it's starting to gain ground here in the US. Well, all right, so we'll see more of that later in terms of applying it to to the actual. Yes sir. All right let's talk about the economics of it is you know you have to, if is it's an alternative to building with concrete blocks or with wood and yet you still have to have a crane involved in it and you got to pay something for these -- what are these."

" cost. Well a raw container used only a few times one roughly 4200 to 5600 dollars depending on the volume. With the value add that we do to the system the overall of particular unit you see here as a roughed in dried in framing package will be. be anywhere forty to 45 dollars a square -- foot. Wow. So can spend 45 dollars a square foot on putting in the house together does that include the skin of the house on the roof roof. it It the exterior, skin of the house, sitting prove it includes the ceramic insulative coatings. a -- The balance of the home for its fit and finish. The foundation and the the trusses will need he supplied by the general contract contractor. -- see, So how many of these are floating around the world. -- if there's seventeen million -- TEU, were twenty foot equivalent unit containers around the world in use today today. and And the US. U.S. our imbalances because we we consume far more than we export we're building up at one time we haven't in the neighborhood of 700000. 700,000 TEU in the USA, and on the the books. 700,000 containers -- idle and the books just empty sitting in the ports of America. And you're saying the main reason is because we we we don't manufacture anything anymore except rubbish and yes so we don't have anything to export in them. And but who paid for. Well American consumer the American consumer. I am confident has the cost of the idle equipment built into the cost of the goods report so it's so.. It's a salvage business that we're looking at. In many ways yes sir or recycling or green business are or a business business. Now place them all down and what will be the next step in terms of building this house -- envelope. to place them down then to permanently weld them to the plates that are embedded in the foundation. And then where we're standing there will be soon. Joist panel in fill going along here in -- yes sir. And and then of course the the sub flooring on top of that and so sure now while that's once that's taken place. The the staining of the exterior some other fellows can come in and start to drywall. Some roof trusses can go up -- and conventional construction sometimes one job is waiting on in the right it's a very fast system that's one of the big advantage is not a but also. Caesars -- sturdy items when when you think about hurricanes yes sir they're going to perform very well right yes sir and they're built for about the hostile. Maritime. Dynamic environment aboard a ship and yet here there permanently affixed to a stationary foundation and I think as important. Steel construction is gaining ground in residential construction. But that's light gauge steel construction and here's a heavy gauge steel construction solution that is approximately the same cost -- we'll look at those early adopters to consider their choices terrific."

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Building Progress on the Converted Shipping Container Home
Building Progress on the Converted Shipping Container Home

Bob Vila recaps the construction done so far of a storm resistant home in St Petersburg, Florida, where abandoned shipping containers have been converted to modules for affordable housing. Bob stresses the importance of building storm ready homes in Florida, where hurricanes are an annual problem. Bob recounts how America has become a nation that imports more goods than it exports, leading to an oversupply of abandoned shipping containers. Technology has been used to convert these steel boxes into modules for building homes. Bob recounts how Bartlett Park in St Petersburg is undergoing a revitalization, leading to a need for affordable housing for first-time homebuyers. This project demonstrates how shipping containers can be converted for building affordable, storm-ready homes. This house uses four steel sections, called Intermodal Steel Building Units (ISBU's), that were trucked to the site. The units were specially modified at Tampa Armature Works, lowered into place, and welded onto plates installed in the concrete foundation. The conventional truss roof system was bolted to the containers. The roof is secured with special hardware recommended by FLASH (Federal Alliance for Safe Homes) to resist hurricane-force uplift.

Building Affordable Homes from Shipping Containers
Building Affordable Homes from Shipping Containers

Bob is in St. Petersburg, Florida, to tour a finished affordable home after completing projects in other parts of the country. The St. Petersburg container-built homes are part of a pilot project involving the use of idle steel shipping containers converted for use as housing units. The goal of the program is to create structurally sound homes that can withstand hurricane conditions. St. Petersburg contains an amazing variety of home styles that developed as people settled from all over the country during the early 20th century. The streets are lined with modest to medium-sized bungalows, Mediterranean-style homes, prarie-style cottages, two-story Dutch Colonials, and some Federal revivals to go with the true Florida bungalows. Along North Shore Park and Coffee Pot Bayou there are grander versions of the same styles. Most of these developments were built out during the 50s and 60s and the character of the housing has been well preserved. Bartlett Park, just south of downtown, was built as a working class retirement neighborhood in the 1920s. It has had a period of decline and problems with crime and poverty until a few years ago when the city and St. Petersburg Neighborhood Housing Services took action. With the Home Depot Foundation and the Federal Alliance for Safe Homes, the houses were adopted as pilot homes to see if it is feasible to use this technology to build affordable and storm-ready housing. Bartlett Park was once a depressed neighborhood, but is now experiencing a dramatic revival. Affordable housing and support for first-time home buyers is creating the "pride of place" needed to keep a neighborhood healthy and sustainable. This house was trucked onto the site in four sections, or "intermodal steel building units." These ISBU's are modified to meet the needs of the plan. The ISBU's were craned onto the foundation and welded to steel plates installed in the concrete. The conventional truss roof system was bolted to the containers. Each truss is attached with special hardware to resist hurricane-force uplift. The space between the ISBU's has been filled in with conventional construction. Steel sheathing was put in place, windows were cut, and the edges of the steel were ground down. The exterior walls were primed before stucco with a super-insulating coating called SuperTherm. SuperTherm prevents the walls from conducting heat, keeping the building comfortable and energy-efficient. On the last visit here, Bob talked with the architect for the project to get a feel for the space.

The Future of Building with Steel Shipping Containers
The Future of Building with Steel Shipping Containers

Bob talks with David Cross formerly of Tampa Armature Works, now of S G BLocks, the company that has taken these abandoned shipping containers and converted them into home-building units. This building technology has a bright future. Since the units first aired on the show, Cross has received well over 500 inquiries about building with ISBU's. There are two more orders in production for military systems in the Caribbean islands, the Redondo Beach house in California, and a possible 600 unit development in southern California. These units are all intended to be affordable. The construction being planned is intended for multi-family and stand-alone housing.

Layout for a Container-Built Home
Layout for a Container-Built Home

Bob talks to Steve Armstrong, the project architect and engineer, about converting old shipping containers into houses. Armstrong recounts how he was approached by Tampa Armature Works to get approvals from the city for the project. When completed, it will be a four-bedroom, two- bath home occupying around 1,600 square feet. The interior is very open, allowing for a high ceiling and lots of flexibility in layout. Bob reviews which sections of the home are part of the original steel containers and which are new steel partitions. The roof is a traditional truss system. The floor is a steel joist construction with traditional plywood decking. The challenge of building a home like this is marrying new methods of construction with traditional methods to create a conventional-looking family home. Armstrong reviews how the steel containers' corner posts form the backbone of the home, holding it all together. Bob and Armstrong review the future interior layout of the home. Armstrong emphasizes that this solves the problem of extra shipping containers while creating much-needed affordable, storm-ready housing.

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