Insulframe Specifications
For Walk-in Coolers and Walk-in Freezers

The following information is intended to aid specification writers, architects, and food service consultants with projects that require prefabricated modular cold storage vaults.

General

Walk-in coolers and walk-in freezers to be constructed with prefabricated panels formed to exact size as described below and manufactured by Kysor Panel Systems, Fort Worth, Texas.

Insulation

Insulation shall be 100% rigid urethane. Urethane is to be poured in place with a density of 2.2 pounds per cubic foot. The at temperature conductivity factor (K factor), overall coefficient of heat transfer (U factor) and the R value to be as follows:      

This insulation shall be a listed urethane with a rating of no more than 25 for flame spread and 450 for smoke developed per ASTM E84. This urethane will also meet the requirements of ASTM D-1929.

Modular Panel Construction

All modular insulated panels to be constructed with die-formed interior and exterior metal pans securely fastened to a tongue-and-grooved perimeter frame of klin dried spruce-pine-fur (SPF) specie, #2 grade lumber. Perimeter frame to feature tongue-and-groove profile for positive alignment and sealing. Modular insulated panel shall be filled with poured-in-place urethane which securely bonds to metal pans and perimeter frame creating a rigid structural panel. Standard panels shall be interchangeable for ease of assembly. Special panels (if required) shall be manufactured to the size required to obtain a specified vault size.

Panel Fastners

Cam-lock fasteners shall provide a tight and positive seal. These fasteners reduce on-the-job installation time to a minimum. Fastener material shall be steel housing, hook and pin with high-pressure die-cast zinc cam. Hardened steel hexagonal wrench is provided to tighten panel fasteners. The hook of the fastener shall engage over the pin when rotating the wrench and with cam-action, draw the panels tightly together. Polyethylene snap-in caps cover the wrench holes. Lock spacing shall not exceed 48" on center.

Panel Gaskets

Each joint shall exhibit a polyvinyl chloride (PVC) bulb type; double lined compression gasket to eliminate water vapor permeability. All gaskets are factory installed and require no additional handling. Gaskets shall be resistant to chemical corrosion and ultraviolet radiation. Gasket operating temperature shall be -34 degrees C to +71 degrees C (-30 degrees F to +160 degrees F).

Finishes

Interior and exterior metal pans are available in a variety of metal types and finishes including:

Galvanized Steel

• Non-Painted Embossed 26 gauge
• White Embossed 26 gauge Black
• Embossed 26 gauge
• Tan Embossed 26 gauge

Stainless Steel

• Stainless Steel type 304, #4 finish, 22 gauge

Galvalume

• Non Painted Embossed 26 gauge

Aluminum

• Non Painted Embossed 0.040 inch
• White Embossed 0.040 inch

Special paint colors and smooth finishes for panels are available upon request. Standard floor finish to be .080 inch Smooth Aluminum over 1/2" CD-X grade plywood.

Optional Floor Finishes

• "Low Profile" Aluminum Tread Plate
• 22 GA. Smooth Stainless steel type 304 #2B finish
• 18 GA. Smooth Stainless steel type 304 #2B finish
• 16 GA. Smooth Stainless steel type 304 #2B finish
• 14 ga. Steel Diamond Tread field installed over standard floor finish - Design for high abuse areas
• 3/16 Aluminum Diamond Tread field installed over standard floor finish - Design for high abuse areas

Doors and Sections

Door and door panel to be of the same general construction and insulation as wall and ceiling panels. Door shall be of the inset type. Direction of swing to be specified. A heated vent shall be provided in or adjacent to all freezer door sections. Door to feature a polyvinyl chloride (PVC) bulb type, double lined magnetic steel core gasket on three sides for a positive seal. Door to have adjustable vinyl wiper gasket for seal at threshold. All gaskets to be easily replaceable and resistant to damage form oils, fats, water, and detergents. Doors can be provided in the following sizes:

                  30" X 78" 34" X 78" 42" X 84" 48" X 84"

                  54" X 84" 60" X 96" 72" X 108"

Hinges

(Doors less than 48" in width) Shall be cam-rise, lift-off hinge consisting of a pressure die cast strap and flange with a brushed satin surface chrome finish. Bearing to be composed of cam and follower made of self-lubricating nylon (Zytel). The hinge set features a spring-assisted operation to facilitate closing. Two (2) hinges will be provided per door.

(Doors 48" or greater in width) Shall be heavy-duty strap style cam-rise with pressure die cast flange and cold rolled steel strap. Pin and cam to be made of carbon steel and shall not require lubrication. Flange to be satin chrome plated. Strap to be zinc plated. Two (2) hinges will be provided up to 54" door. Three (3) hinges will be provided for 60" door and four (4) hinges for 72" door.

Latch

Shall be pressure die cast body with a brushed satin surface chrome finish. Latch to be provided with provision for padlock (padlock not provided). Latch to have recessed inside safety release to prevent entrapment.

Dial Thermometer

Shall be flush mounted in door section. Dial thermometer to have 2" diameter face and a temperature range of -40 to +60° F. Finish to be polished chrome.

Anti-Condesate Heaters

Freezer door sections are equipped at both sides and top with U.L. approved concealed fiberglass-silicone heater wires. A sill heater is located in bottom of door to avoid damage caused by loading at threshold plate, and to insure contra-ambient control by locating heat at the precise location of thermal transfer. A threshold cover plate (sill) is supplied to cover the breaker strip running beneath the door. The heater wire is easily replaceable.

Lighting and Electrical

Door section may be provided with a factory-installed vapor-proof light fixture on the interior of the section and a light switch with pilot light indicator flush-mounted within a chromed steel plate on the exterior. All wiring within the door section - heater, switch, and light fixture - is installed by Kysor Panel Systems in conduit per the N.E.C. and requires only simple field connection by others for complete operation. All components to be U.L. approved. An electrical listing label will be applied to all prewired sections. Service required is 120 volt, 60 cycle, 1-phase.

Partitions

Common partition walls are available for dual temperature or multi-compartment walk-ins and are attached to adjacent wall panels by the use of cam action locks secured within special sections formed by those panels.

Screeds

A factory provided screed is available for units without prefabricated floor. Depending on application, the screed will be one of the following:

• Concealed strip screed
• PVC Channel
• 1-1/2" X 1-1/2" aluminum structural angle
• 1-1'2" X 1'1/2" 18 galvanized steel angle

PVC channel and aluminum angle meet NSF requirements. An NSF approved coved base can be provided for other screed types.

Alternate and Option Equipment

Kysor Panel Systems can provide an array of pertinent equipment to complete any project and provide a single source installation.

• Heated Vent: Must be specified for all walk-in freezers operating at a temperature of 32 degrees F. or lower. A heated vent shall be provided to equalize the difference in exterior & interior pressure caused by sudden temperature changes due to opening doors, loading products, & the defrosting of coils. The heated vent shall be located above the freezer door (or located in a side panel, away from the direct air stream flowing from the evaporator). Electrical service required is 120 volt, 60 cycle, 1-phase.
• Door Window: A 12 3/4" x 12 3/4" or 12 3/4" x 22 3/4" (viewing area) observation window can be provided in the cold storage doors. Window shall consist of three (3) panes of glass with sealed spaces between them & shall be removable for replacement. Electrical service required is 120 volt, 60 cycle, 1-phase. (Windows may be provided with heaters if required.)
• Meat Rails: Units shall be double (or single) meat rails of 3/8" x 2" plain (or galvanized) steel rails. Movable meat hooks, one (1) per lineal foot of rail, shall be supplied. If required, meat rails can be provided with 18" shelf and brackets.
• Hinged Glass Display Doors: Each door shall be constructed of an extruded, polished aluminum frame and shall contain at least two (2) panes of glass.
• Low-temperature doors shall have built-in heaters to eliminate condensation. Medium temperature doors are available with heated glass when specified for use in buildings with high humidity and without air conditioning.
• Doors shall be of the lift-in, lift-out type for easy cleaning. They shall be self-closing and shall contain magnetic gaskets to provide a tight seal. Hardware shall consist of concealed hinges and a handle with attractive contemporary styling. Interior fluorescent lights shall be provided at each mullion to properly illuminate the display area. A junction box shall be provided for 120 volt, 60 hertz, 1-phase, A.C. service.
• Shelving (if applicable) shall be provided behind each door opening. 5 tiers are provided unless specified otherwise.
• Audio-Visual Alarm: Alarms can be provided for each compartment and shall work in the following manner: When the interior compartment temperature approaches the undesirable range, a digital readout display flashes & an audio alarm sounds. Electrical service required is 120 volt, 60 cycle, 1-phase.
• Large Dial Thermometer: Provide surface-mounted dial thermometers with a range of minus 40 degrees F. to plus 60 degrees F. The thermometers shall be 3 1/2" in diameter & chrome plated.
• Vapor-Proof Light Fixture: Incandescent vapor-proof lamp holder & lexan globe shall be mounted to the ceiling panels (as shown on plans) & shall be connected to a 3-way switch & pilot light which shall be mounted on the exterior of the door sections. Electrical service required is 120 volt, 60 cycle, 1-phase. Installation & wiring shall be performed after the unit is installed.
• Locking Bar: Provide a cadmium plated locking bar on each door to prevent entrance to the walk-in cooler/freezers even if hinges are removed. Provide bar with a safety release handle to prevent anyone from being locked inside. (Stainless Steel finish is available upon request.)
• Strip Curtain: Reinforced polyester strip curtains shall be manufactured of clear extruded vinyl with rounded edges. The curtains shall be suitable for applications with temperatures as low as minus 20 degrees F. & shall be made for any of KPS's standard sizes of hinged or sliding cold storage doors.
• Ceiling Supports: All ceiling panels shall be supported in accordance with the manufacturer's recommendations and the Architect's approval. Various support systems are available including:

Interior steel (wall or column supported)

Exterior steel (wall or column supported)

Wire or all thread suspension

• Soffit Closure Panels: Provide closure panels of materials matching the exposed exterior of the walk-in cooler/freezer for installation between the top of the insulated wall & the underside of the existing building finished ceiling (as indicated on the plans). Closure trim of matching material can be furnished wherever a space exists between the panels of the walk-in cooler/freezer and other building walls or columns.
• Cantilever Shelving: Shelving shall be an adjustable cantilevered type furnished in the length, width, and number of tiers specified. All components to feature heavy gauge steel construction. Shelving is available in galvanized, painted galvanized or stainless steel finishes. Construction will meet NSF standards when specified. Shelving to be of single piece construction and available in lengths up to 10'0". Shelves are available in depths up to 30". Uprights shall be fabricated from two (2) 14 gauge, rolled steel channels, continuously seam welded. Brackets to be fabricated from 12-gauge steel. Uprights and brackets to be Electro-zinc plated and chromate dipped to assure against rust and corrosion.
• Free-Standing Modular Shelving With Posts: Shelving shall be an adjustable type furnished in the length, width, and number of tiers specified. All components to feature heavy gauge steel construction. Shelves shall be fabricated of bright basic carbon steel or stainless steel rod. A rigid framework will extend around all four (4) sides and extend along the length of each shelf. At each corner of the shelf there shall be a tapered collar welded to the rigid framework. Each shelf shall have heavy gauge rods on 1" centers from front to back. Construction will meet NSF standards. There shall be a weld at every contact point between rods and between rods and rigid framework. Posts shall be made of 1" O.D. tubing and with a 16 gauge steel wall. Posts shall have grooves at 1" intervals for locating shelves. Posts to have a plastic cap at the top and a leveling bolt at the bottom. Shelving and posts are available in the following finishes: zinc and chrome plated, epoxy coated or stainless steel.
• Mechanical Door Closer: Shall be of heavy-duty steel construction with hydraulic mechanism. Devise automatically brings door to full closed position whenever door is ajar, within 10 of closed position.

Composite Testing

Kysor Panel Systems has panels available that meet the requirements of the following: 

• National Sanitation Foundation Standard #7
• Accepted by the United States Department of Agriculture
• Toxicity per UPITT Protocol
• Electrical application per U.L. 471, NFPA 70 and CSA C22.2
• Flame spread and smoke developed per UL-723, ASTM E-84 and Chapter 26 of all the National Building Codes
• Ignition properties per ASTM D-1929
• Factory Mutual Standard 4894
• Miami-Dade County- South Florida Building Code
• City of Los Angeles-Municipal Building Code
• City of Houston-Houston Building Code
• City of New York-Material and Equipment Acceptance
• State of Oregon-Prefabricated Structures
• State of California-Licensed Manufacturer
• State of Wisconsin-Material Approval

Regulations and Codes

All work and materials shall be in full accordance with local and/or state ordinances. Kysor Panel Systems is not responsible for furnishing items required by the regulations, but not specified or shown on the drawings or contained in the specifications.

Refrigeration

A complete section of engineered refrigeration, from self-contained systems to remote components and accessories is available from Kysor Panel Systems to satisfy exacting requirements - for indoor or outdoor application.

Warranty

Kysor Panel Systems guarantees purchaser the structural panels are free of defects in material and workmanship for a period of one (1) year.

Contact Us

KYSOR Panel Systems
P.O. Box 14248
Fort Worth, Texas 76117
Phone: (800) 633-3426