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Making a box from cement board

A

Any name you wish

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Jan 13, 2022
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Central Arizona
I have 4 3ft by 5ft hardi boards I want to make into an enclosure. I know I need some additional structure and insulation as this sits outside on a concrete pad in AZ. I have room to go 3ft wide by 5 ft tall. Will be housing the batteries, inverter, and SCC.
 
Are you looking the structure, period? Or are you wanting it to be fireproof? 2x4 stock is easy and various ways to join it together. Angle iron is harder but will not catch fire. Insulation, and possibly cooling, are another thing.

Best to plan for the structure, the siding, water resistance (rain and flood), the insulation, access, weight bearing capacity of the walls, security, access, fire resistance, and cooling all at once before you buy anything else. It’s a medium big project. All the best.
 
Any name you wish said:
Materials aren't really the question. I am having issue visualizing it better to see how I want to make it. Any examples to follow?
Click to expand...
With these 3 tools you can build just about anything out of metal studs

A pair of tin snips
A screw gun
Locking C Clamp




If you just want to build a box

ee0d0c34a3270c47e7b9cb530df16ec3.jpg










If you want to frame the inside walls of your plastic shed



metal-stud-framing-5.jpg
 
Just an FYI:

The metal studs in the pics I posted are NOT load bearing.

They do make structural metal studs that are load bearing but I imagine they are a little pricey.
 
TomC4306 said:
We can't really hold your hand on this.
Click to expand...
Then don't. I am looking for examples, things that worked well and didn't. I am seeking information from people with experiences on what they have done. I know generally what I am looking for, but hope to further expand my horizons from people who are willing to share their thoughts or experiences on projects they did. Feel free to share if you have any.
 
It does sound like a good idea. Area I have to work with is 2 foot deep so maybe the one Will recommended for a battery shelf has a slightly smaller version? May be overkill for my setup as well.
 
I'm stacking 2 Trophy 220ah batteries vertically. 60" high x 20" length x 10" wide. So I'm fitting 440ah of 48v batteries in a 20" x 10" footprint. Taking advantage of height and the ability to use the batteries in the vertical position.
 
If you want to get fancy, a window unit would keep it cool. Or a 12 volt ice box with lid open.
 
Funny that I’m doing the same analysis for my little power house. but space not an issue. All roads keep leading me to a new shipping container.
 
Bluedog225 said:
Funny that I’m doing the same analysis for my little power house. but space not an issue. All roads keep leading me to a new shipping container.
Click to expand...
My neighbor has a mini shipping container thingy that she got when she bought the house. If she ever gets rid of it, I have dibs. I hate waiting though.
 
There are videos on youtube where people test the cement board secured with wood studs. The wood studs are not affected because the cement board shields them.
 
If space isn't an issue I'm using the large Dewalt shelf unit:
IMG_0047.jpeg
I cut polycarbonate sheets that fit perfectly over the wire shelves and cement board also cut to fit nicely underneath the shelf to prevent any "accidents" from affecting cells on shelf above it. The bottom and top shelves have 2" thick rock wool underneath the shelves for insulation. I'm somewhat enclosing this shelving unit on 3 sides with plywood and then have rock wool up against the plywood for insulation, safety, and fire protection.
 
While looking for some other types of designs I came across these.
1673027803078.png
High side is 75 inches, low is 61 inches. 48 inch width, 40 depth. Can frame the outside and create an inner frame with the cement board on the inside. Sloped roof can hold more solar if I so choose. $60 for the frame. Supposedly it is 3/4 inch square tubing. Thoughts?
 
Any name you wish said:
Wanting something that is fire retardant, and insulated to maintain temps better
Click to expand...
If you read the product data hardiboard states that it is not suitable for fire resistant uses.
NEpowerandlight said:
do make structural metal studs that are load bearing but I imagine they are a little pricey.
Click to expand...
Steel studs are not that expensive on the grand scale of things imho.

Even the ‘light’ commercial studs if laterally braced with pieces of the stud channel for such a small structure as what you are describing would be strong enough to accept some weight. Those are like 26 or 29 gage or something.
In commercial applications doubled 5/8” sheetrock is often hung on 20ga steel studs and supports a few hundred pounds of light fixtures and hvac louvres etc in the ceilings with vertical stud wall systems supporting so… that and rockwool as suggested seems a good idea under 5/8MR. Horizontal sections of 20ga screwed to the walls or located in stud channel could act as shelving support.
Any name you wish said:
While looking for some other types of designs I came across these.
$60 for the frame. Supposedly it is 3/4 inch square tubing. Thoughts?
Click to expand...
That’s super inexpensive
I’d be inclined to send the hardiboard to Facebook marketplace or Craigslist and use exterior drywall and a pail of synthetic stucco instead. Insulation is not accomplished well with 3/4” but you could tight fit 3/4” foil faced and sheetrock the interior afterwards
 
12VoltInstalls said:
If you read the product data hardiboard states that it is not suitable for fire resistant uses.

Steel studs are not that expensive on the grand scale of things imho.

Even the ‘light’ commercial studs if laterally braced with pieces of the stud channel for such a small structure as what you are describing would be strong enough to accept some weight. Those are like 26 or 29 gage or something.
In commercial applications doubled 5/8” sheetrock is often hung on 20ga steel studs and supports a few hundred pounds of light fixtures and hvac louvres etc in the ceilings with vertical stud wall systems supporting so… that and rockwool as suggested seems a good idea under 5/8MR. Horizontal sections of 20ga screwed to the walls or located in stud channel could act as shelving support.

That’s super inexpensive
I’d be inclined to send the hardiboard to Facebook marketplace or Craigslist and use exterior drywall and a pail of synthetic stucco instead. Insulation is not accomplished well with 3/4” but you could tight fit 3/4” foil faced and sheetrock the interior afterwards
Click to expand...


I see we both worked in commercial construction. Retired after 35 years in a Philly trade union.

I assume most people have not worked with metal studs and probably will try to source them at home depot. So the selection is as limited as there experience with metal studs.

It sounds like the OP wants to make an insulated battery box inside of a plastic shed due to heat build up in those hot AZ summers.
 
NEpowerandlight said:
probably will try to source them at home depot
Click to expand...
Ya, stock is probably not consistent or dependable at HD.
In BTV Vermont they had 20ga stocked and I made an assumption that was normal. Buuuuuttt then again it’s Home Depot and they don’t know what stuff is. In the northeast H,Depot calls nelma S-P-F stamped spruce studs “white wood” and 1/2” douglas fir plywood is differentiated as ‘western pine’ I guess because their other plywood is actually ‘southern pine.’
 
NEpowerandlight said:
I see we both worked in commercial construction. Retired after 35 years in a Philly trade union.

I assume most people have not worked with metal studs and probably will try to source them at home depot. So the selection is as limited as there experience with metal studs.

It sounds like the OP wants to make an insulated battery box inside of a plastic shed due to heat build up in those hot AZ summers.
Click to expand...
I want out of the plastic box. I have the box covered currently on a enclosed patio on my porch. I am looking to move it outside to get it away from the house, then insulate it for heat while also helping to keep the flame possibilities down.
 
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