EPS Molders

Cold Storage Low temperature space is classified by

on the service conditions. The
According to the US Department of Agriculture, construction and design of the cold
there was over 3.04 billion gross cubic feet of storage facility depends on the needs of
general refrigerated or cold storage capacity in each classification.
2001.  These facilities are essential for the safe •Coolers - Above 0ºC (32ºF)
handling and storage of food products and other •Coolers - Below freezing to minus 2ºC
goods.  Without a storage area that provides a (28ºF)
consistent environment that can sustain its integrity, •Freezers - Minus 23ºC (-9ºF) to minus
many products would not be readily available to 33ºC (-29ºF) - Constant temperature
consumers. •Sharp Freezers - Cycle from room
temperature down to minus 40ºC (-
Expanded polystyrene insulation board is ideal for 40ºF)
use in walls and roofing systems in the •Cryogenic Service - Below minus
construction of cold storage space. These facilities 100ºC
store food, flowers, and other temperature sensitive
commodities. The temperatures range from normal room temperature 20ºC (68ºF) to
cryogenic temperatures -100ºC (-148ºF). As the surface (of what?) temperature
decreases, the quality of construction and sustainability required becomes more
critical.

  The performance properties of EPS, including constant

thermal resistance, dimensional stability, chemical inertness
and sustainability, make it well suited for use as insulation.
Additionally, its closed-cell structure provides minimal water
absorption and low vapor permeance; an important design
consideration for damp environments.

Cold storage insulation is normally applied in 2 layers with joints staggered between
layers and boards tightly butted.  The EPS boards must be firmly and permanently
bonded to the wall, ceiling, and roof using adhesives.  The first layer of floor
insulation is bonded to sub-slab while the second layer is installed dry.  Thicker
coatings of heavy bodied adhesives may be used to provide some straightening or
bridging on an irregular wall surface. Adhesives are applied to provide 100% contact
and to fill any voids. Spot or strip applications of adhesives are used only where a
vapor or air barrier is installed.

All components of construction must work together to achieve a system that will
enclose space and hold it at the desired temperature for extended periods of time
without any deterioration. For instance, it is recommended that any lumber
incorporated into cold storage construction be pressure treated with a wood
preservative.

Ensuring a low temperature, the space must be

properly enclosed and equally important, the removal
of heat generated from refrigeration equipment and
other machinery. There are several methods that can
be employed to eliminate heat sources from the space
to reduce maintenance problems.

To achieve maximum insulation efficiency and long-

term performance, mechanical equipment may be

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EPS Molders

adapted for the cold temperatures.  Refrigeration units can be reduced in size to
decrease the amount of heat generated.  And, they should have an automatic
defrosting cycle.  Other items such as pumps, fans and lights should also operate
properly.  The thickness and type of insulation in the construction deters the
movement of outside weather and normal self-generating building heat.

The use of doors plays a large role in the ability to sustain the appropriate
temperature.  The frequency of door opening and closing is of greater concern than
the size of the door. Operational guidelines should be established to quickly expedite
the loading and unloading of product in the cold rooms. Forklift truck operation and
other mechanical systems allow quick opening and closing doors with mechanical or
remote operators.  The investment on doors can result in energy savings by
decreasing the amount of heat transfer. Holding areas with a regular door outside of
the cold room can also help reduce the flow of warm air into a cold area.

Contractors must be aware of unsealed openings around electrical conduit and

equipment hangars, structural cracks and poorly constructed joints at the wall -
ceiling line, construction joints, etc.  Warm air can infiltrate the storage area through
these imperfections compromising the environment.  When warm, moist air enters a
freezer room it can cause a rapid build up of ice, which can force movement of the
structure.

Frequently, goods entering the facility have a higher temperature than that of the
storage area.  Design provisions must be incorporated in the refrigeration unit to
remove the newly introduced heat.

In the same respect, any modifications to the design or operation of the building or
special care in workmanship which lowers heat gain within the cold room will reduce
the load on the refrigeration equipment which can effect noticeable energy savings. It
is critical that the necessary prevention of heat gain can be assured at the design
stage to minimize the refrigeration equipment needed.

The construction must be tight so that is no air movement through the structure from
the outside to the inside of the room. The location of air seals and vapor barriers can
be cold storage rooms. The movement of water vapor must be restricted by the use
of vapor barriers or by the vapor barrier characteristics of EPS rigid foam insulation. 
The placement of air seals and vapor barriers in the construction is imperative to
reduce the possibility of leakage.

Expanded polystyrene insulation meets extensive model building code requirements. 

More than 48 EPS manufacturers with hundreds of locations in the U.S. and Canada
maintain numerous listings at Factory Mutual (FM), Underwriters Laboratory (UL),
Underwriters Laboratory of Canada (ULC) and other testing facilities.

  Copyright ©EPS Molders Association 2009  

The EPS Molders Association
1298 Cronson Boulevard
Suite 201
Crofton, MD 21114
             800.607.3772      

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