Falcon Structures

Behind every polished project photo is someone standing in the Texas heat trying to capture a steel box in the best possible light.

A little behind-the-scenes from our latest shoot. 📷

The elusive 40-foot double-wide container workspace in its natural habitat: a large-scale industrial processing site. Notice how it blends into its surroundings, offering a cooling shelter in the summer sun. Requiring only a flat foundation and utility hookups to thrive, it serves an important role for respite and well-being in the wild industrial manufacturing landscape.

Sometimes the details that look simple take the most engineering to get right.
This storage container was built with insulated overhead doors to help meet energy code requirements while still allowing for large, practical access openings. Not all “insulated” roll-up doors are created equal, and these provide meaningful thermal performance compared to standard coiling doors.
Also… they just look cool.
Purpose-built solutions tend to do that.

Translating construction-based skills into manufacturing standards is harder than it sounds.

Framing, drywall, electrical… they’re all the same skills you'd see on any job site. But in a factory environment, the expectation is repeatability, precision, and documented process. Those two worlds don't naturally speak the same language.

One of the tools that helps us bridge the gap: the A3 methodology.

Named for the 11"×17" paper it lives on, A3 forces an entire problem-solving cycle — problem, root cause, solution, implementation, review — onto a single page. Being constrained to that one piece of paper forces us to nix any vagueness, getting to the root of the problem.

Our Co-Founder Brian Dieringer put it simply: "We're trying to be a learning organization. This is one of our tools to learn."

The companies that will win in modular and manufactured construction aren't the ones who make the fewest mistakes. They're the ones who build the best systems for learning from them.

How A3 Methodology Improves Shipping Container Manufacturing The A3 methodology is a lean manufacturing problem solving tactic used by Falcon Structures to efficiently manufacture modified shipping containers.

Tiny container. Big responsibility.
This 10-footer is designed to enclose industrial and aerospace-grade 3D printers, with a clean, controlled environment that doubles as a relocatable testing space.

Portable lab, meet space tech. 🧑‍🚀🌖

Several Falcon team members drove down to San Antonio for the annual National Portable Storage Association (NPSA) conference and trade show. These guys joined other industry leaders to sit in on educational sessions, network, and see what’s new in the world of portable storage.

Nothing beats getting out there and seeing what others are building and solving!

Not your typical 20-foot office.
Two-toned paint, picture windows, diamond tread steel flooring, and a private bathroom all come together in a durable, ready-to-deploy workspace that moves with the team.