Designing Efficient Cold Storage Facilities: Unveiling the Power of IMPs and Key Considerations
Since the COVID-19 pandemic, online grocery shopping has gained popularity and this demand for online shopping is expected to continue to increase. According to the Best Practices in Cold Storage Facility Development publication, published by NAIOP in 2021, online grocery sales increased 54% in 2020, reaching a total of $95.8 billion, and are expected to see a yearly increase of least 17% through the year 2024. This increase demand for online grocery shopping will certainly create more demand for the construction of new cold storage warehouses. Additionally, the publication also mentioned that it is estimated that over 100 million square feet of cold storage space will be built in the U.S. between 2020 and 2025 which translates to a 47% increase. When it comes to designing a cold storage facility, every detail matters. The success of such facilities hinges on a delicate balance of structural and material choices, all working in harmony to preserve perishable goods. In this blog, we'll delve into the intricacies of cold storage facility design, with a particular emphasis on the use of Insulated Metal Panels (IMPs) and the essential considerations that guide the process.
We'll begin our journey by exploring why IMPs are the material of choice for cold storage facilities, and from there, we'll dive into the crucial design considerations. From selecting the right panel thickness to making informed decisions about doors and ceilings, each step in the design process can impact the overall efficiency, energy savings, and longevity of your cold storage facility.
Join us as we navigate through the world of cold storage design, uncovering the hidden factors that can make or break the functionality and success of these vital spaces. Let's embark on this journey to understand why IMPs are an ideal choice and how they intersect with key considerations in cold storage facility design.
Why are IMPs such an ideal choice?
Since the goal of cold storage facility (or is mainly responsible for) is to preserve perishable goods such as food, pharmaceuticals, and other temperature-sensitive products, which are subject to safety requirements, there is higher importance for using high quality building materials. As noted in the previously mentioned NAIOP publication, cold storage facilities are expected to remain functional for as long as 50 years or more. For these reasons and many more, IMPs are an excellent choice of material when designing a cold storage facility. Some of their advantages include highest insulating value per inch of all available insulating solutions, lower energy consumption, speed of installation, cost effectiveness, long lasting, ease of cleaning and maintenance as well as flexibility of design.
SOME KEY CONSIDERATIONS
Choosing a Panel thickness: Many different elements need to be taken into consideration when deciding on the panel thickness. The main considerations are:
- Building code energy efficiency requirements
- The required R value (see the table below)
- Whether it’s a cooler or a freezer
- The surrounding rooms must also be taken into consideration
Choosing the right panel finishes: Since, the interaction between your stored goods and their surroundings can lead to corrosive effects, make sure to choose the proper finish to address this concern. Our solutions address this challenge through our specialized finishes, such as the resilient Advantica® L Control finish. A PVC laminate specially formulated to meet the most stringent requirements of atmosphere-controlled environments such as food processing, preparation, storage, and packaging. Also, white panel finishes are recommended because they contribute to a better lighting, and they require a fewer number of light fixtures.
Vapor barrier and moisture control: If there isn’t a proper moisture control in your facility it could cause many problems. It would represent safety hazards for employees in the facility, damaged products, and reduced refrigeration equipment efficiency. IMPs designed with interlocking tongue and groove, fully thermally broken joints that can meet strict weather barrier requirements by adding butyl sealant in the panel joints. For cold storage, having panel joints properly sealed acts as a barrier against moisture. The panel joints must be properly sealed in order to prevent moisture from infiltrating.
To prevent this kind of issue from happening, a good panel joint control is key. There are multiple options available to seal panel joints (factory or site applied butyl, silicone bead, permanent foam gasket). They all offer different level of weathertightness that should be considered in the sizing of refrigeration units and pressure relief vents.
Load-bearing capacity and support structures:
Depending on the building configuration, storage room sizes and design specifics, it may be needed to support the ceiling panels (for long span ceilings). If possible, a simple suspension system designed to hang from the building roof structure may be sufficient. It is important to validate the required walking loads (on the cold storage ceiling), but also, ensure that the building can handle this additional weight. In scenarios where it is not possible to suspend the panels from the building roof structure, a self supported design may be required. This design should be defined with the panel manufacturer to ensure the safety of the occupants and a thermally efficient design.
Fire safety and compliance:
Foam plastics used in IMP are not all of the same chemical composition: Some products offer highly efficient thermal efficiency and low risk for flame spread and smoke development, that meets the building code enforced in the region where panels are installed.
Choosing the right doors
Choosing the right doors for your cold storage facility is crucial in order to ensure low energy and operation costs. Additionally, the choice of doors will also have an impact on moisture control. Depending on the room usage the door gives access to, we might need to look at other key points when selecting a door:
- Maintaining temperature integrity
- Easy access and safety (by using motorized sliding or rollup doors)
- Resistance to wear and tear (by using the proper door frame that match the type of circulation)
Norbec offers a wide range of doors. The following models are most commonly used doors in cold storage facilities:
- Hinged
- Sliding
- Roll up doors
- Traffic doors
Multiple door accessories are available upon request.
Ceiling Design
Our ceiling panels, often known as self-supporting ceilings, have the capability to cover spans of up to 12 feet without the need for extra support. Nevertheless, for safety considerations, it’s essential to firmly affix ceilings wider than 12 feet to the underlying structure. These panels can adhere to pedestrian traffic regulations when constructed in accordance with specific guidelines, making it easier to access for maintenance purposes. Furthermore, we offer the choice of concealed ceiling suspensions specifically designed for Norex-L panels.
Closing the Cold Storage Design Chapter: Embrace IMPs and Elevate Your Facility
In the ever-evolving world of cold storage facility design, choosing the right materials can make all the difference. IMPs have emerged as an unparalleled solution, offering an array of benefits such as superior insulation, lower energy consumption, rapid installation, and design flexibility.
Throughout this blog, we've delved into some of the critical considerations when working with IMPs. We've also emphasized the pivotal role of insulated metal doors and ceiling design in achieving the best results for your facility.
As you embark on your cold storage facility design journey, remember that every choice you make contributes to the overall performance, energy efficiency, and longevity of your facility. Whether it's safeguarding perishable goods or ensuring compliance with industry regulations, IMPs and the right design elements can be the key to your success.
Norbec demonstrated its expertise by building some of the most demanding cold storage projects such as Ninth Avenue Foods and Congébec.
For further product inquiries or design consultations, don't hesitate to contact us at local technical sales representative.
- Information from ASHRAE (2018)
- Information is based on proprietary insights obtained within Norbec which reflects ASTM C518 testing results.
- Extruded Polystyrene Foam Association’s Comparison of XPS and EPS Foam Insulation.
