What we designed and built

The client needed a solution that enables testing of their new battery system and could be easily moved between sites. The testing containers required a stable and controlled temperature with special ventilation and fire protection to meet industry standards. Due to the battery racks’ weight the floor required a reinforced floor structure to withstand the loads.

We started the project by selecting two new 10ft HC shipping containers, which were then equipped slightly differently to match the client’s needs. Both units share the same safety and climate-control backbone. W e installed fire-resistant EI90 insulation in the double doors, walls and ceilings, and added 50 mm XPS insulation underneath the floors. Each container received an air heat pump so that the indoor temperature can be easily adjusted year-round. The outdoor units were protected with custom shelters, and plastic pipes were used to guide condensate water neatly down to ground level instead of dripping down the container wall.

For continuous, controlled ventilation, we installed two new supply air valves with filters on opposite walls. These adapt automatically to temperature differences and form the fresh air intake. Exhaust air is handled by a powerful 100A duct fan connected to a stepless thyristor speed controller. To take ventilation a step further, separate CO₂ sensors were added inside the containers and linked to the duct fans. When the CO₂ level rises above a set limit, the fans automatically increase their capacity and keep running until the air quality has returned to the default level.

Electrical and Equipment Integration

Inside the equipment spaces, we installed LED lighting and three double 230V sockets in each container to power the client’s equipment. Both containers are supplied via a 16A/400V power connection, and the kill switch and manual controller for the duct fan are mounted in a protective case on the outer wall for safe and easy access. For cabling, we cut a 500 × 500 mm opening and multiple Ø25 mm holes, making it simple to route cords in and out of the container.

The key difference between the two units lies in the floor structures. In the first container, the standard plywood floor was reinforced by adding a 3 mm aluminum tear plate on top, improving point load capacity and weight distribution. In the second container, the floor needed to carry even higher loads. The original plywood floor was removed completely, exposing the cross members. Extra support beams were welded at a 90-degree angle to these cross members, creating a much stronger base. On top of this structure, we installed a 3 mm galvanized steel plate and finished it with the same aluminum tear plate as in the first container. This second unit also received two floor drains that lead water out through plastic pipes attached to the bottom siderail.

Highlights of this build

• 2pcs new 10′ HC shipping containers

• The standard plywood floor in the first container was covered with aluminum tear plate

• The standard plywood floor in the second container was replaced by the combination of 3mm galvanized
  steel plate and aluminum tear plate

• 100mm thick EI90 on the ceiling, walls and the double doors

• 50mm XPS insulation beneath the floor

• 2pcs supply air valves with filters and cover grilles

• 100A duct fan hooked up with a CO2 sensor

• Air heat pump

• 2pcs LED lights

• 3pcs 230V double sockets

• Power supply 16A/400V

• Protective case with a kill switch inside