1. General Description of the System
Karmod Flat Pack Container is an innovatively designed container that can be packed / unpacked and assembled / disassembled easily in a short period of time. Packed parts of the system occupy minimum space and hence many of them can be shipped in the same container, which is especially convenient for international transportation. Standard size of flat pack containers is 2300 mm x 5950 mm x 2500 mm (Width x Length x Height), however, they can be manufactured in custom sizes within our production limits. The bolted design of the system also allows multiple flat pack containers to be connected to each other in order to construct single-storey and multi-storey buildings, where a flat pack container is the modular structural unit. You may find general properties of flat pack containers in the following sections.
2. Production
The main structural frame of the flat pack containers consists of cold-formed steel profiles. Steel sections are cold-formed, a process increasing the load carrying capacity of steel sections, from flat ST37 steel sheets using the state of the art roll-form machines. Only galvanized high quality steel sheets conforming to DIN EN 10326 are used in the production of cold-formed steel profiles. Karmod’s roll-form machines are fully automatic and are able to manufacture error-free steel members (error tolerance = 0.6 mm) including the bolt holes. Production does not involve welding.
Structural design calculations are performed by our engineers before the production of structural members in accordance with the space function, internal & external effects and national & international design standards. Environmental effects (snow, wind, temperature, etc.) and seismic effects in the region and customer expectations are taken into consideration in the structural design process, which is conducted with the help of several advanced design & analysis software, e.g. Sap2000, XSteel, CFS and in-house programs.
Below are the main design parameters we use for standard flat pack containers:
Ø Snow load (Max.): 80 kg/m²
Ø Wind speed (Max.): 102 km/hr
Ø Live load for residential buildings (Max.): 200 kg/m²
Ø Live load for commercial buildings (Max.): 350 kg/m²
2.1. Bottom Frame (Chassis)
Ø Lower eyebolts are manufactured from 4 mm galvanized steel sheets.
Ø Thickness of temporary support elements is 2 mm.
Ø Features of the cement-bonded particle boards (Betopan) used in the floor:
- Size: 1250 mm x 1000 mm
- Thickness: 16 mm
- Density: 1300 kg/m³
- Thermal conductivity coefficient: 0.15 W/mK
- Bending resistance: 9N/mm²
- Elasticity Module: 4500N/mm²
- Fireproof (B1 DIN 4102)
Ø Betopan is bolted to the steel frame with galvanized screws
Ø Vinyl (used for floor coating) is 3 mm and attached with special glue
2.2. Top Frame (Chassis)
Ø Thickness of eyebolts is 4 mm
Ø Glass wool is placed inside columns and beams in order to avoid thermal bridges
Ø Top chassis is bolted to the columns and hence it can be assembled & disassembled easily
Ø PVC paneling is used in the ceiling
2.3. Columns
Ø There are 4 columns, one in each corner and they are bolted to eyebolts of upper and lower frames with nut screws. 8 nut screws are used to connect the column to the chassis in each corner.
Ø Downspouts with a diameter of 40 mm (PİMAŞ) are placed in the columns for storm water drainage.
2.4. Walls
Features of the polyurethane sandwich panels used in the walls:
Ø 1000 mm x 2250 mm (Width x Height)
Ø 40 mm thick polyurethane, 0.50 mm thick outer and 0.40 mm thick inner sheet (micro-ribbed)
Ø B2 Fire rating (EN 13501-1, DIN 4102)
Ø 38 kg/m³ density (EN 1620, DIN 53420) with ±2 kg/m³ error tolerance
Ø -200°C to +100°C Heat resistance
Ø 30-100 Vapor resistance (EN 12086, DIN 4590)
Ø 95% Closed cell percentage (EN14509, DIN4590)
Ø 100 KPa and 400 KPa Mechanical strength (EN1607, DIN18159)
Ø 2% Water absorption in 168 hours (EN ISO 354, ASTM E203)
Ø 0,022 W/mK Thermal conductivity coefficient (EN12939, ASTMC518)
Ø Sheets are coated with RAL 9002 polyester paint. Thickness of coating is 20 microns and thickness of the primer is 5 microns
Ø Supports for the air conditioner are specified in the technical drawings
Ø DX51 D+Z (EN10327, DIN 17162/1&2, ASTM A653)
Ø 500 N/mm² maximum tensile strength (EN10327, DIN 17162/1&2, ASTM A653)
Ø 22 mm minimum ultimate elongation (EN10327, DIN 17162/1&2, ASTM A653)
Ø 200-280 gr/m coating (hot dipping) (EN10327, DIN 17162/1&2, ASTM A653)
3. Foundation Design
Flat pack containers are light structures and they do not require deep foundations. The foundation will be prepared by the customer although Karmod provides the customer with foundation plan and reinforcements. A flat concrete slab is usually enough, however, it is recommended that spread or strip footings are used to elevate the container and minimize the contact with the concrete foundation for energy efficiency. Footing dimensions and layout are included in foundation plans.
4. Thermal Design
Karmod flat pack containers are designed to attain the best energy and insulation performance considering the environmental properties of the region, in which the structure will reside. High quality sandwich panels and glass wool installation in the joints prevent thermal bridges. Standard flat pack containers comply with Turkish Energy Efficiency Standard (TS825) and can be comfortably used in most of the worldwide locations without modifications. Heat transfer coefficients (U Value) of standard flat pack container components are specified below.
Ø External walls: 0.47 kcal/m²hr°C
Ø Internal walls: 0.45 kcal/m²hr°C
Ø Roof: 0.68 kcal/m²hr°C
Ø Floor: 3.85 kcal/m²hr°C
Thermal performance can be improved at the request of customer for extreme environmental conditions, where the standard features are insufficient.
5. Electrical Design
Flat pack container panels do not have built-in wiring, cable canal and electrical equipment, which are installed over panels. Below are the features of the electrical equipment used in standard flat pack containers:
Ø Lighting wires are 2 x 1.5 mm² NYM
Ø Power socket wires are 3 x 2.5 mm² NYM
Ø 2x18 watt fluorescent light fixtures are used for internal lighting. Fixtures are covered with globe for waterproofing in wet rooms
Ø Each container has power socket and switch
Ø Fuse box with 4 slots, residual current circuit breakers and 25x25 PVC cable canals are included
6. Plumbing Design
Ø WC sinks have a size of 370 mm x 450 mm
Ø Hot water is available in WC
Ø Western style toilets are equipped with flux boxes and waste water is discharged from the back side
Ø There is a shower tray (800 mm x 800 mm), faucet and shower head in the bathroom
Ø Drinking water pipe & fittings are PPRC and waste water pipe & fittings are PVC
7. Doors
Ø Frames and wings of all doors are made of painted steel sheet; inside door is made of MDF
Ø External doors are 900 mm x 2000 mm and internal doors are 800 mm x 2000 mm
Ø External doors lock (Kale brand)
Ø Metal hinges of doors are 100 mm x 25 mm. The hinges are coated with RAL 9002 and available as four pieces
8. Windows
Ø Frames and wings of all windows are made of galvanized steel sheet and PVC windows
Ø Inside opening windows are 80 cm x 110 cm and are single-wing
Ø Double-glazed windows: Double 4 mm thick glasses + 9 mm spacer bar
9. Packaging
All flat pack container parts are well-packed and shipped as a single package, where everything fits between top and bottom chassis. Temporary corner beams are placed between upper and lower frames to fix the package. Package sizes are 2300 mm x 5950 mm x 450 mm (Width x Length x Height).
Package content: Bottom chassis, top chassis, 4 columns, sandwich wall panels, sandwich door panel, sandwich windows panels, electrical equipment, skirting boards and cable canal.
10. Other Items
Ø All metal surfaces are painted with double coating, double layer synthetic paint (Ral 5002).
Ø PVC skirting boards are installed at the bottom edges of the panels and other edges are closed with 20 mm x 60 mm PVC cable canals.