How to Safely Remove a Shipping Container Wall and Install a Roll Tarp Door
Removing an entire sidewall from a shipping container creates valuable access for storage, equipment, and industrial applications. However, once the corrugated steel is removed, the container must be structurally reinforced to safely support the roof and anything stored inside.
In this project, The Container Guy team installed a 40-foot roll tarp door, reinforced the container structure, and built a hazardous material storage unit with containment pans, explosion-proof electrical components, and modular strut framing.
Why Use a 40-Foot Roll Tarp Door?
A roll tarp door is one of the best options when you need full side access while still being able to close and secure the container. Unlike standard cargo doors, a roll tarp door allows equipment and materials to be loaded through almost the entire length of the container.
Factory-built open-side containers are designed with a reinforced floor and large structural header to span the opening. When modifying a standard shipping container, similar structural considerations are required.
For this build, the team retained the bottom C-channel and additional floor structure to create space for containment pans and bar grating. A steel skid was also installed underneath the container to help support the floor once the sidewall was removed. A center post was added as an additional precaution.
Reinforcing the Container After Removing the Sidewall
Removing the corrugations eliminates much of the original sidewall structure. The roof may appear strong while the container is empty, but the floor and roof can flex significantly once equipment, chemicals, or other heavy materials are added.
The container was reinforced with a steel skid underneath and additional structural members in the floor. The team also divided the opening with a center post rather than attempting to leave the entire 40-foot span unsupported.
The exact reinforcement required will depend on the container condition, opening size, roof loads, floor loads, and intended use. Structural modifications should be reviewed appropriately before the container is put into service.
Manual Roll Tarp Doors for Hazardous Storage
The roll tarp door was installed with a manual operating system instead of an electric kit. Since this container was being prepared for hazardous and potentially flammable materials, the team wanted to avoid introducing a 12-volt motor and battery that could create a spark.
The manual system uses a full-length pipe that rolls the tarp up above the opening. The tarp is held tight against the container with securing bands. Operators should be careful when opening and closing the door because the mechanism stores considerable torque.
Modular Strut Framing for Electrical and Interior Equipment
Before installing equipment on the walls or ceiling, the container was lined with Container Modification World's modular strut system. The team used MSS 1-Way Brackets and MSS 2-Way Brackets to create vertical strut lines and overhead mounting points.
This allows electricians and other trades to install equipment, conduit, lighting, and accessories without drilling through the container shell or damaging the exterior coating. The same system can be used inside larger containers for shelving, electrical distribution, lighting, and other equipment.
Explosion-Proof Electrical Components
Because the container was designed for hazardous material storage, the electrical system required specialized components. The team installed explosion-proof lights, vapor-proof connectors, and sealed switches to reduce the chance of vapors reaching a potential ignition source.
The electrical connectors were packed with specialized putty to seal the wiring entry points. These installations require more time and care than standard electrical work, but that additional attention is important when storing flammable chemicals.
Containment Pans and Removable Bar Grating
The floor was fitted with welded containment pans designed to hold spilled liquids. The pans were water tested, repaired where necessary, and tested again until the leaks were resolved.
Removable bar grating was installed above the pans using Hilti clips and self-tapping screws. This creates a working surface while still allowing individual grating sections or the entire floor to be removed for cleaning after a spill.
The finished container combines structural reinforcement, full-length access, modular interior framing, explosion-proof electrical components, and liquid containment into one purpose-built storage solution.