Structural Optimization of Sandwich Container Shelter Panels in harsh Nordic environments

Abstract

This thesis focuses on the structural optimization of sandwich panels used in mobile container shelters, particularly the one that TAM AS produces, which is the TAM Brakka mini-3.5m. The main goal is to optimize the shelter’s structural design to achieve the best possible strength-to-weight ratio, which means to reduce weight and improve the stiffness of the floor, roof, and wall panels without reducing its strength and performance.

Using the theory from “Optimal Stiffness Design of Sandwich Plates with Variable Core Densities”, by Dag Lukkassen, Annette Meidell, and Herman Myrvoll, the optimization is done by adjusting the face sheet thickness and core density and to minimize deflection under distributed loads. The best materials were selected using Granta EduPack, comparing them with the two core types from TAM AS which are the Divinycell H60 and Jackon XPS 400. While the numerical simulations are computed using ANSYS Mechanical APDL and then validated with the analytical results.

Two designs are compared: the original “existing” and the optimized “adjusted” floor, roof and wall panels. The final optimized panels design resulted in up to 22% to 23.42% reduced deflection and saved about 10.084 kilograms across all panels or 3.77% deviation from the existing design, while maintaining strength and stiffness within the allowable design limits. The ANSYS numerical simulation results closely matched the analytical computations, with differences typically under 7% to 11%, which confirms the reliability of the model. These improvements lead to container shelters that are easier to transport especially by helicopter and suitable for use in harsh Nordic climates.

The findings could benefit TAM AS and other manufacturers by helping produce lighter, more energy-efficient, and cost-effective shelters for use in construction, military, emergency response, and remote communication setups.