Transforming a Shipping Container Into a Modular Solar Power Station
This 20-foot one-time-use shipping container is far from a basic storage unit. It has ten 540-watt solar panels, batteries, inverters, a generator, and a climate-controlled interior designed to support a large mobile power system.
The project was built for a specialized customer, but many of the lessons learned are being used to develop future DIY products from Container Modification World.
Building a Mechanical and Equipment Room
The container is divided into two main spaces.
One side is a mechanical room containing equipment such as a transformer and air-conditioning condenser units. The other side is climate-controlled for sensitive electrical equipment.
Because condensation could form in the mechanical room, the original plywood container floor was removed and replaced with 1 1/4-inch bar grating.
The bar grating allows condensation to drain while also creating airflow through the floor.
A galvanized partition wall separates the two spaces.
Strut Channel Framing and Interior Finishing
Container Modification World’s strut channel framing system was used throughout the interior.
Strut Strapping provides attachment points for white PVC Re-Line wall panels, which create a bright and durable Class A flame-spread interior finish.
The system also gives installers plenty of mounting options for electrical equipment, cable trays, and other components.
A Container Modification World Dual Swinger Man Door provides access to the sensitive equipment room.
T16 Exhaust Fan and Controlled Ventilation
Ventilation plays an important role in keeping the equipment inside this container at a safe temperature.
Four 10-inch Intake Dampers were installed in the partition wall and paired with a T16 Exhaust Fan.
The 16-inch AC Infinity fan fits between the strut framing and helps pull outside air through the system when conditions allow.
This creates a more efficient cooling strategy because the system can use cool outdoor air instead of relying on air conditioning all the time.
Developing a Modular Solar Panel Mounting System
The most unique part of this build is the adjustable solar panel mounting system.
The first version grouped multiple solar panels, but the assemblies were too heavy and difficult to operate safely.
After several redesigns, each solar panel received its own individual mounting section.
Container Modification World Strut Channel, MSS Angle Brackets, bearing wheels, spring nuts, and adjustable stops were used to create a system that allows each panel to move independently.
The panels can be secured flat against the container for transportation or opened to approximately 45 degrees for better solar exposure.
Improving Highway Transport
One of the biggest challenges was keeping the solar panels secure while the container travelled down the highway.
Grab handles were added along the lower edge of the panels to support their weight during transport.
Eye bolts were also installed so the panels could be strapped tightly against the container.
The goal is to eventually refine this into a simple clamping system that makes deployment and transportation even easier.
A 135 kW Mobile Power System
The finished system is rated for a maximum output of approximately 135 kW at three-phase 480 volts.
Inside the container are multiple Sol-Ark inverters, battery packs, large electrical panels and a PLC-based automation system.
The controls monitor outside temperature and humidity and automatically select the most efficient method of heating or cooling.
The system can use outside air, air conditioning or other heating and cooling stages depending on environmental conditions.
Turning Industrial Innovation Into DIY Solar Products
This project required three major iterations of the solar mounting system, but each version helped improve the design.
Container Modification World products used throughout the build include MSS Angle Brackets, the Dual Swinger Man Door, and the Solar Panel Mounting Kit.
The long-term goal is to take what was learned from this advanced solar power station and create smaller, more affordable systems for homeowners and DIY builders.
A modular shipping container solar system could eventually allow someone to start with one solar panel and continue expanding the array over time, creating a flexible path toward grid supplementation or complete off-grid power.