Cold Storage & Controlled Env Using Insulated Metal Panel PDF

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Cold Storage and Controlled Environments Using Insulated Metal Panels
Presented by: Kingspan Insulated Panels

726 Summerhill Drive
DeLand, FL 32724
Description: Thermally controlled environments such as cold storage freezers and coolers, and food processing and packaging
facilities take many different forms. Their performance and functionality depend on their project-specific
requirements and can be affected by the conditions the materials and systems are subjected to. This course
discusses how insulated metal panels (IMPs) perform the necessary functions to provide an effective energy-
efficient building envelope and why they are suitable for use within temperature-controlled hygienic environments—
where performance is critical.
To ensure the accuracy of this program material, this course is valid only when listed on AEC Daily’s Online
Learning Center. Please click here to verify the status of this course. If the course is not displayed on the above
page, it is no longer offered.
The American Institute of Architects · Course No. AEC1170 · This program qualifies for 1.0 LU/HSW Hour.
AEC Daily Corporation is a Registered Provider with the American Institute of Architects Continuing Education System (AIA/CES). Credit(s) earned on completion of this program will be reported to
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education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling,
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©2018 ∙ Table of Contents < Slide 2 of 57 >

AEC Daily Corporation has met the standards and requirements of the Registered
Continuing Education Program. Credit earned on completion of this program will be
reported to RCEP at RCEP.net. A certificate of completion will be issued to each
participant. As such, it does not include content that may be deemed or construed to be
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Purpose and Learning Objectives
Purpose:
Thermally controlled environments such as cold storage freezers and coolers, and food processing and packaging
facilities take many different forms. Their performance and functionality depend on their project-specific requirements and
can be affected by the conditions the materials and systems are subjected to. This course discusses how insulated metal
panels (IMPs) perform the necessary functions to provide an effective energy-efficient building envelope and why they are
suitable for use within temperature-controlled hygienic environments—where performance is critical.
Learning Objectives:
At the end of this program, participants will be able to:
• define the functions of the building envelope and explain how IMPs perform these functions by providing all four
essential environmental control layers—water, air, vapor, and thermal
• explain the thermal performance advantages of IMPs to demonstrate why they are ideally suited for use on the exterior
and interior of controlled environments—from food and beverage processing to the storage of pharmaceutical supplies
• examine the different types of coatings used on IMPs for compliance with the regulations of the Food Safety
Modernization Act (FSMA) and U.S. Department of Agriculture (USDA) and Safe Quality Food (SQF) standards, and
• describe key installation details for the use of IMPs for all aspects of controlled environments, including key design
criteria such as tolerances, load support, and span capability.

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Contents
Architectural Insulated Metal Panels (IMPs)
IMPs in Controlled Environments
Design Criteria and Installation
Case Studies
Summary

Architectural Insulated Metal Panels (IMPs)

Environmental Control Layers
Building envelopes, also known as building enclosures, are

environmental separators—they separate an interior environment
from the exterior one. As such, they are exposed to a variety of
environmental loads including wind pressure, solar radiation, and
rain. As the world demands more from buildings in terms of energy
efficiency, fire safety, weather resilience, occupant comfort, and
aesthetics, the design and construction industries are using a range
of design elements and systems to control the environmental loads
acting on buildings.
For optimum performance, environmental separators should include:

▪ a water control layer
▪ an air control layer
▪ a vapor control layer, and
▪ a thermal control layer.

Environmental Control Layers
Architectural insulated metal panels (IMPs) are designed to create a complete energy-efficient thermal envelope. IMPs
provide all four control layers in a single, factory-built component, simplifying installation with fewer trades and transitions
and less chance of failure.
Water Air Vapor Thermal
Controls rain and Control of air leakages Manages movement of Controls heat transfer,
groundwater intrusion, including air-transported vapor (diffusion), even maintains conditioned
protects from elements moisture without air movement interior environment
Closely related to
operating/energy costs,
occupant comfort, and
sustainability

What Is an IMP?
This detail shows the base concept of Consistent R-value

over the service
an IMP—a factory-formed, single- life of the building
component panel that provides a barrier
layer from the exterior to the interior of a
room or building.
Single component
IMPs are composed of an insulated core
material, typically a foam made of either Continuous insulation
(no gaps or pockets)
polyisocyanurate (PIR), polyurethane
(PUR), or polystyrene (PS). The foam is Moisture resistant
Factory-applied, long-
bonded between two metal skins, lasting finishes
utilizing an interlocking joint for a
weathertight system and a guaranteed
R-value. They can be installed by a Accelerated build speed,
single subcontractor significantly faster reduces on-site time by
up to 50% vs.
than conventional multilayered walls, conventional construction
saving time and money.

What Is an IMP?
An IMP features a tight-fitting interlocking joint that enhances

airtightness, preventing thermal bridging and condensation over
the service life of the building.
During construction, the double-lapping, interlocking labyrinth

joints are progressively assembled to provide continuous
insulation across an entire wall or ceiling. This results in a
prescribed R-value, per the thickness of panel, that is consistent
across the surface without any thermal breaks.

IMPs in Temperature-Controlled Environments
IMPs are ideally suited for environments where precise temperatures must be maintained. The exterior and interior skins
of an IMP function as water, air, and vapor barriers, plus the two-stage joinery provides effective vapor management. By
effectively managing the movement of vapor and eliminating warm air from infiltrating temperature-controlled
environments, the IMPs can provide high and consistent R-values around the entire temperature-controlled enclosure.
According to an Oak Ridge National Laboratory study, cool walls can result in a 10% reduction in required cooling energy.
Cool walls can be accomplished through using cool colors with high solar reflectivity and high emissivity. Solar reflectivity
is the ability of a material to reflect solar energy back into the atmosphere. Emissivity is a material’s ability to release
absorbed energy back into the atmosphere, on a scale from zero to one. In general, the duller and blacker a material is,
the closer its emissivity is to one. The more reflective a material is, the lower its emissivity. This is the main reason most
cold storage applications and buildings are white.
IMPs are resistant to conductive heat transfer when exposed to solar heat. They limit the transfer of heat from the exterior
to the interior, resulting in reduced solar heat gain and allowing for energy-efficient interior conditions that can be precisely
controlled.

IMPs in Temperature-Controlled Environments
The key to the design of cold storage Cool walls can result in a 10%
facilities is a tight seal on the warm side reduction in cooling energy required.
of an IMP—to mitigate vapor drive and Solar Reflectance:
prevent conductive energy from The fraction of solar energy that is
reflected by the wall
entering the building.
The sun’s radiation hits the

wall surface
Replace panel with
new 3″ joint panel
Less heat is absorbed by

the wall and transferred
into the building
Thermal Emittance:
The relative ability of the wall surface to
radiate absorbed heat

IMP Construction
As an alternative to traditional, multicomponent cladding systems, a single-component IMP system increases speed of
build and minimizes delays and the need for multiple trades. The single-component panels form the basis of complete
building envelope systems that maximize thermal performance while simplifying design and construction.
Single-component construction allows evaporation from both exterior and interior skins. Since the interior panel face
temperature is above dewpoint in properly conditioned buildings, there are no concerns with condensation on the interior
side. Additionally, interstitial (between the layers) condensation is not possible because air cannot enter the closed-cell
foam, nor between the foam and the facings.

IMP Insulation Core: Design Options
The type of material used to insulate the building envelope of a temperature-controlled environment has changed over
time. Early designs used wood- or fiber-based materials and cork compositions. Advances in building material science
and construction technology have created core materials for IMPs with high thermal resistance characteristics that meet
or exceed building codes for flammability and combustibility while providing insulating thermal barriers. Some optional
cores for IMPs include the following:
• machine-made mineral fiber (MMMF)
• expanded polystyrene (EPS), also known as bead-board or white-board
• used where build cost is of a primary concern and where R-value and fire resistance may not be as important
• extruded polystyrene (XPS)
• meets some of the basic building code requirements; tends to be used for long-span conditions
• polyurethane (PUR)
• a rigid, closed-cell material where thermal performance values increase
• polyisocyanurate (PIR), also known as polyiso or ISO
• a poly(urethane-isocyanurate); allows for high R-values and good fire characteristics

IMP Insulation Core: Design Options
While assisting to reduce energy consumption and carbon emissions of

a building, thermal insulation and preinsulated panels can impact
climate change and ozone depletion if they are not manufactured in a
responsible way. An insulation’s impact on ozone depletion and climate
change is characterized by its ozone depletion potential (ODP) or global
warming potential (GWP).
With increasing demands for products categorized as zero GWP and

zero ODP, the IMP market is expected to move toward more hybrid
polymer networks as the core material. Hybrid polyisocyanurate (PIR)
has a closed microcell structure—a polymer comprising two or more Hybrid
networks that are at least partially interlaced on a polymer scale but not PIR PUR MMMF
covalently bonded to each other. Hybrid PIR systems provide higher
levels of thermal performance and fire resistance, all with lower
environmental impact. The thickness of insulation needed to achieve
U=0.20 W/m2K


Controlled Environments
Controlled environment IMP systems are designed for use within temperature-controlled, hygiene-safe environments,
including any facility that falls under the U.S. Food and Drug Administration (FDA) or U.S. Department of Agriculture
(USDA) guidelines. This means they can be used in cold storage freezers and coolers and in food processing and
packaging facilities, including the sorting and storing of fresh fruit and vegetables, the primary and secondary processing
of meat, fish, and poultry, and the processing of seed and feed for agricultural purposes. In addition to the food and
beverage and agricultural sectors, controlled environment IMP systems are used in cold/chill storerooms and cleanrooms
for the biotechnology and pharmaceutical industries.

Attributes of IMP Systems in Controlled Environments
When looking at wall, floor, and ceiling assemblies or systems for controlled environment applications, the following
attributes of the assembly or system should be considered:
• precise thermal control – the system must be able to maintain the required temperature without adding extra load on
equipment or energy to provide the desired temperature
• hygienic surface coatings – the surface coatings must resist moisture ingress and minimize potential for toxic mold
or bacterial growth, and meet USDA washdown criteria when required by the application
• high R-value – the system should provide the best possible thermal envelope by reducing thermal bridging to provide
an unbroken shield against heat transfer
• airtight and weathertight – the system must remain both
air- and weathertight over the life of the building to prevent
heat gain (or heat loss)
• structural performance – ensure the system meets the
requirements for the application
• fire performance – foam insulation products provide a Class 1
(or Class A) fire rating, which means that the building material
does not spread flames quickly and is highly resistant to fire

Cold Storage Design with IMPs
The design of cold storage facilities is based on Table 2: ASHRAE Recommended R-Values of Insulation (ASHRAE 2002)
the guidelines and regulations in ASHRAE 90.1,
Thermal Resistance,
“Energy Standard for Buildings Except Low- Temperature R, °F ft2 h Btu-1 (m2 K W-1)
Type of
Rise Residential Buildings,” and ASHRAE’s Facility
Range,
°F (°C) Walls/Suspended
2005 book “Design Essentials for Refrigerated Floors
Ceilings
Roofs
Storage Facilities.” Note, there may also be 40 to 50 Perimeter 25 30 to 35

Cooler
state or local energy codes that need to be (4 to 10) Insulation Only (4.4) (5.3 to 6.2)
considered when designing a controlled 25 to 35 20 24 to 32 35 to 40
Chill Cooler
environment structure. (–4 to 2) (3.5) (4.2 to 5.6) (6.2 to 7.0)
–10 to –20 27 to 32 35 to 40 45 to 50
Holding Freezer
(–23 to –29) (4.8 to 5.6) (6.2 to 7.0) (7.9 to 8.8)
Table 2 from “Design Essentials for –40 to –50 30 to 40 45 to 50 50 to 60
Blast Freezer
Refrigerated Storage Facilities,” on the right, (–40 to –46) (5.3 to 7.0) (7.9 to 8.8) (8.8 to 10.6)
shows that the thermal resistance of all of the
components (floor, walls, and ceiling) of a
controlled environment need to be considered when designing a cold storage facility. Using a standard mechanical
load and the climate requirements (holding temperature) of the controlled environment, a thermal resistance value
can be determined as to the type and thickness of IMP that will be suitable for a specific project.

Food Safety and IMP Systems
In 2011, U.S. food safety laws were transformed when the FDA Food Safety Modernization Act
(FSMA) was signed into law. The FSMA shifted the culture of food safety from reacting and
responding to microbial contamination after it had already occurred to preventing it from happening
in the first place. Human food and animal food growers, producers, harvesters, and processors
must comply with FSMA regulations to ensure specific actions are taken at every point in the food
supply chain to prevent contamination and protect the well-being of the food system.
Food manufacturing owners are initiating Safe Quality Food (SQF) standards per the FSMA, which
require architects, designers, contractors, and manufacturers to address the long-term
performance of finishes exposed to “wet-processing” and “washdown” environments.
IMP systems for controlled environments were developed to specifically address FSMA standards
and to meet SQF standards and Food Safety and Inspection Service (FSIS) requirements for
sanitation design of noncontact areas in food zones.

Food Safety and IMP Coatings
The coatings on IMPs used in temperature-controlled environments

and cold storage have particular properties suited to different Agri Zone
+20°C to +80°C 30–95% RH
environments. When determining the right coating for a specific
project, it is necessary to consider the classification of the corrosive Fire Zone
+20°C to +80°C 30–95% RH
environment and type of activities that will occur within the facility.
Clean Zone
+18°C to +24°C 40–60% RH
The corrosive factors of an internal environment are determined by

Food Zone
the presence of corrosive chemicals and/or microorganisms in the +10°C to +18°C
internal atmosphere and by the relative humidity, as well as by the Leisure Zone
frequency of cleaning; aggressiveness of the cleaners, degreasers, –2°C to +14°C
and sanitizers; and the methods of cleaning. Some buildings may Chill Zone
contain areas where different conditions apply and must be 0°C to +5°C
considered separately if they have different corrosive environments. Modular Zone

–40°C to +60°C
Regular inspection and maintenance will ensure the performance of Cold Zone
–40°C to 0°C
the IMPs is maintained. The frequency of inspection is defined by the
corrosive environment classification and type of activities.

To address FSMA requirements for sanitation design of noncontact areas in food zones, wet-processing, and washdown
environments, some IMP manufacturers have developed specific strategies and categories of coatings to help with the
specification process. For example, here is a list of corrosiveness factors, labelled C1 to C5:
C1 – Very Low: Dry environment with no attack from corrosive chemicals and/or microorganisms. Routine cleaning (not
more than once a month) using neutral cleaning agents.
C2 – Low: Environment where condensation may occur, with no attack from corrosive chemicals and/or microorganisms,
although the walls may occasionally be splashed with slightly corrosive liquids. Routine cleaning (not more than once a
month) using neutral cleaning agents.
C3 – Medium: Environment with frequently high humidity and where corrosive chemicals and/or microorganisms are
present. Nonintensive cleaning (not more than once a week) using higher pH cleaning agents.
C4 – High: Environment with constant high humidity and where high concentrations of corrosive chemicals and/or
microorganisms are present. Intensive cleaning (not more than once a day) using higher pH cleaning agents (pH 5–9).
C5 – Very High: Environment with permanent condensation and where high concentrations of corrosive chemicals and/or
microorganisms are present. Intensive cleaning (not more than once a day) using higher pH cleaning agents (pH 5–9).

This table shows examples of types of facilities, recommended inspection periods, and the suitability of the coating for
each corrosive environment classification. It is provided for general guidance only. Consult individual manufacturers for
information about the effects of various chemicals on the coatings used on their IMP products.
Type of Coating
Inspection SMP FRP
Corrosiveness Type of Application PVDF Stainless
Frequency (silicone- (fiber-
(polyvinylidene
modified
difluoride)
reinforced Steel
polyester) plastic)
C1 Dry-packaged cold storage, docks, locker rooms, toilets,

Very Low Annually Yes Yes Yes Yes
offices, shops
C2 Storage, sorting and packing of fruit and vegetables, storage
Low Annually – Yes Yes Yes
of packaged meat and dairy products
C3 Food production and preparation areas, dry process, ice
Every 6
Medium cream production, butter production, breweries, dairies, wine – – Yes Yes
months
cellars, processing of precooked foods, baking facilities
C4 Wet process industrial kitchens and cooking, storage of
Every 3
High unpacked fish, cheese, meat cutting, scalding and – – Yes Yes
months
evisceration
C5 Every 3 Primary live rooms, rendering, picking, cooking, preparation of
Very High – – – Yes
months marine products

Example: IMP Coating in Controlled Environment
This slide shows a silicone-modified polymer (SMP) coating

system. Beginning at the base, the system starts with
corrosion-resistant steel that has been zinc plated on two sides. Topcoat
Next, a pretreatment is applied to the steel. This is followed by Primer
a primer. Finally, the topcoat—a chemically inert silicon Pretreatment
polyester paint—is applied to the panel.
Zinc/A
Metal Substrate
The result is a panel finish that is: Zinc/A
• suitable for surfaces immediately adjacent to food

preparation, processing surfaces, or equipment and meets
USDA requirements for noncontact surfaces
• easy to clean and nontoxic SMP Coating
• resistant to bacteria, mold growth, and staining
• durable, and
• chemical and humidity-corrosion resistant.

Examples: IMP Coating in Controlled Environment
PVC Film
Adhesive
Pretreatment
Zinc/A
Metal Substrate
Zinc/A Primer
Unpolished Line Brushed Pinpoint Finish
Antimicrobial PVC Coating Stainless Steel

Topcoat is a chemically inert antimicrobial polymer film, laminated to Chemically inert, crevice-free, austenitic stainless steel,
pretreated metal, and specifically developed for controlled specifically developed for controlled environments and highly
environments. Suitable for surfaces immediately behind food corrosive environments. Suitable for surfaces in slaughterhouses,
preparation and processing surfaces or equipment. mushroom cultivation, cooking rooms, drying rooms for cheese,
and laboratories for bread-making.

Example: IMP Coating in Controlled Environment
Some food-related facilities require extremely stringent

standards for health and safety and must comply with
Hazard Analysis Critical Control Point (HACCP) and other 0.090 FRP
governing regulations to ensure proper washdown Adhesive
procedures are followed in order to prevent any outbreaks Pretreatment
of bacteria.
Zinc/A
Metal Substrate
To help buildings comply to these regulations, IMPs are Zinc/A
available with a factory-adhered, laminated, fiberglass-

reinforced plastic (FRP) and sealant system. The FRP
lining protects the metal panel with its dent-resistant
properties and enables the interior of the panel to
withstand extreme washdown procedures required by FRP Coating
HACCP.

IMP Coatings in Controlled Environments: Cleaning and Repair
To maximize performance and maintain high standards of

hygiene, it is necessary that the coatings are cleaned using a
manufacturer’s recommended procedures. The frequency of
cleaning and cleaning agents used are dictated by the types
of activities conducted in any given area. Cleaning
procedures usually include the following steps: preclean,
wash, rinse, disinfect, final rinse, and dry.
Occasionally, through everyday use, IMPs can incur minor

scuffs, scratches, dents, punctures, or indentations. Panel
repairs and surface preparation are important and are
typically carried out by specialist contractors using a
manufacturer’s recommended methods and approved
maintenance paints.

Design Criteria and Installation

Typical Cold Storage Exterior Panel
These details show a typical cold storage panel used for exterior applications. Typically with this type of panel, a
manufacturer will offer several options, including:
• gauge on the exterior, e.g., 26, 24, 22
• gauge on the interior, e.g., 26, 24, 22
• width of the panel, e.g., 24″, 30″, 36″, 42″
• panel thickness, e.g., 2″ to 6″ (dependent on use and R-value required), and
• panel length, e.g., 8′ to 53′.

Typical Cold Storage Interior Panel
These details show a typical cold storage interior panel. Interior panels are applicable for both wall and ceiling conditions
in cold storage buildings, for use as partitions, or to construct a box within a box, e.g., freestanding boxes, small coolers,
and freezers within facilities. Partition panels are designed for internal use only (although external panels can be used
internally). They are typically symmetrical in design and thicker than exterior panels. Similar to exterior panels, a
manufacturer will offer several options, including:
• gauge on the exterior, e.g., 26, 24, 22
• gauge on the interior, e.g., 26, 24, 22
• width of the panel, e.g., 36″, 42″, 45″
• panel thickness, e.g., 2″ to 8″ (dependent on use and R-value required), and
• panel length, e.g., 8′ to 52′.

Standard Tolerances
It is important to talk about the standard tolerances of the IMPs themselves

relative to design criteria. The walls must be square, and support members to
which panels are attached must be in the same plane, flat and free of
obstructions such as weld marks, bolts, or screw heads. The panels must be:
• plus or minus 1/8″ in 5 feet in any direction along the plane of framing
• plus or minus 3/8″ in 20 feet in any direction along the plane of framing
• plus or minus 3/4″ (19.05 mm) from the framing plane on any elevation, and
• plumb and level within 1/8″ at all changes of elevation for transverse bent
corner panels.
It is necessary to verify that bearing support has been provided behind the
vertical joints of horizontal panel systems and the horizontal joints of vertical Correct design and support tolerances ensure
panel systems. The width of the support should be as recommended by the best visual results.
manufacturer. Steel supports should be designed with adjustable connections
to allow proper alignment. Misaligned steel supports can result in air/water
infiltration and unacceptable panel aesthetics, e.g., waviness, oil canning,
framing read-through, etc.

Controlled Environment Enclosure Functions
The functions of the enclosure of a controlled environment can be grouped

as follows:
• Control – control the flow of heat, air, moisture, light, sound, etc.
• Support – manage physical loads imposed by gravity, wind, impact,
thermal expansion, etc.
• Finish – provide interior and exterior aesthetics and protection for control
and support elements

Panel Wall Assembly: Load Support
All IMPs are non-load bearing and should not be

relied upon to provide significant diaphragm strength.
As is shown in this diagram, IMPs in a controlled
environment application must support loads that are
being applied in a variety of unconventional ways, for
example, the thermal load on the exterior vs. the
thermal load on the interior.
When thermal stress is introduced to the outside of

an IMP and the interior holding temperature of the
enclosure is 37°F or even -20°F, what is called a
delta T or temperature differential exists. The
temperature differential induces a bow or thermal
bow, and the panel reacts by cupping or bowing.

Panel Wall Assembly
To design an effective thermal envelope for a

controlled environment, it is necessary to consider
the thickness of the panels and how they are
supported, the color of the panels, and the interior
holding temperature of the enclosed space.
Manufacturers have the ability to take the design

pressures from the building and perform a
component and cladding design review to verify the
correct components are being used. They will create
specifications for the project to ensure that the
desired internal temperature can be achieved and
maintained.

Interior Wall Assembly Panel Span Capability
A span rating of a panel signifies the maximum Interior Partitions Allowable Span Table
recommended center-to-center spacing of supports over
which the panels can be installed to meet building code Temperature Differential Not Considered
requirements. Design pressures, allowable deflection, and Panel Span Allowable Span in Feet
dead and live loads are all considered when establishing Thickness Condition L/120 Deflection Design Load
panel span and the fastening requirements for a particular
project and geography. 2″ Single Span 21′
2.5″ Single Span 25′

Typically, published panel span data uses a common 3″ Single Span 28′
baseline for panel span performance from ASCE 7-10,
“Minimum Design Loads for Buildings and Other Structures,” 4″ Single Span 33′
and takes into account both wind and thermal loads. For
5″ Single Span 36′
example, in this interior partitions allowable span table, IMPs
can be used as a single partition, assuming the wind load 6″ Single Span 40′
(by code) is 5 psf (pounds per square foot) and the
deflection design load is L/120. A 4″ panel can span 33′-0″
unsupported to meet code and design load.

Interior Ceiling Panel Span Capability
A ceiling is designated either as a 3.75″ x 4″ Ceiling Panel Span (psf)

Panel: 300 26/26
nonwalk surface at 10 psf @ L/180 8 ft 10 ft 12 ft 14 ft 16 ft 18 ft 20 ft
Panel Rod
deflection, or a walk surface at 20 Thickness Spacing
psf @ L/240 deflection. 4′-0″ 24.7 14.9 - - - - -
2″
5′-0″ 24.7 14.9 - - - - -
Panel Wt.
6′-0″ 21.5 14.9 - - - - -
2.3 lb/sf
7′-0″ 14.7 10.8 - - - - -
This ceiling span chart is used in
4′-0″ 30.0 19.2 12.6 - - - -
2.5″
conjunction with a T-grid suspension Panel Wt.
5′-0″ 30.0 19.2 12.6 - - - -
6′-0″ 21.3 16.2 12.6 - - - -
system where T6-6063 aluminum is 2.41 lb/sf
7′-0″ 14.4 10.7 - - - - -
used to suspend the panels. The 3″
4′-0″ 39.1 25.8 17.5 12.0 - - -
5′-0″ 32.5 25.1 17.5 12.0 - - -
chart establishes the thickness of Panel Wt.
6′-0″ 21.2 16.0 12.5 10.1 - - -
2.5 lb/sf
7′-0″
panel and the attachments 14.3 10.5 - - - - -
4′-0″ 53.3 39.8 28.0 20.1 14.6 10.6 -

necessary to provide the appropriate 4″
5′-0″ 31.8 24.8 19.8 16.2 13.6 10.6 -
Panel Wt.
span to meet the deign load. 6′-0″ 20.8 15.7 12.1 - - - -
2.7 lb/sf
7′-0″ 13.9 10.2 - - - - -
5″ 4′-0″ 52.1 41.2 33.4 27.8 21.5 16.2 12.3

Panel Wt. 5′-0″ 31.6 24.4 19.4 15.8 13.2 11.1 -
The design pressure values of the 2.89 lb/sf 6′-0″ 20.3 15.2 11.8 - - - -
ceiling span chart exclude the dead 6″ 4′-0″ 51.9 40.8 33.0 27.5 23.3 20.1 17.3
Panel Wt. 5′-0″ 31.4 24.0 19.0 15.5 12.8 10.7 -
load of the panel, which is tested 3.08 lb/sf 6′-0″ 20.1 14.9 11.4 - - - -
with a 300 lb concentrated load. Calculated deflections of the panel/assembly subject to DL + LL (gravity) loads AND limited to L/240; no thermal loads

Exterior Panel Wall Assembly Span Capability
The span capability of an exterior IMP is assessed similarly to Fastener analysis (wind load and thermal load combined)
that of an interior panel, but with a full review of the components Parapet
-21
Load (psf) -21 -21
and cladding design criteria of the building. Geometry, location, Span (ft) 17.2 15 1.5
Base Top
climate, and temperature are all major factors in assessing panel
performance. Shear
Diagram
This chart shows a multispan condition and the complementary Moment

span analysis based on a 5″ IMP with 26/26 gauge both sides Diagram
and a combined wind and thermal load for a freezer application.

Structural Analysis for a One-Foot Panel Width:
The analysis shows panel failure for a 17′-0″ span at 21 psf. The Reaction (lb/ft)
Shear (lb/ft)
-113
-113
-482
248 -234
-113
81 -32
failure was at the connections due to the reactions of the wind Support Moment
(in-lb/ft)
13996 284
pressure and span. A safety factor of 2.0 per ASCE 7-10 has In-Span Moment
(in-lb/ft)
-3635 -1606
been breached in this case indicating the span must be reduced. Distance (in)
Deflection (in)
→ 64.45
-0.945
→ 133.53
-0.628 0.554
Distance (in) → 96.31 → 96.79 → 18.00
Deflection Ratio (L/?) 218 287 65
Typical modes of failure are connection, shear, and buckling.

Panel Design Summary:
Note, external span charts only address wind loading. Consult End Supt. End Supt. Int. Supt. Int. Supt. Shear Buckling Deflection
Connection (lb) Pull-Out (lb) Connection (lb) Pull-Out (lb) (psi) (psi) Ratio (L/?)
the IMP manufacturer in the design phase to determine proper Ultimate Value -673 -6906 -1887 -6906 18.30 24000
Design Safety Factor 2.00 3.00 2.00 3.00 3.00 2.00
placement of the steel based on the temperatures that must be Design Value -337 -2302 -944 -2302 6.10 12000 180
Actual Value -395 -395 -1687 -1687 4.28 11847 218
maintained on the interior. Actual Safety Factor 1.70 X 17.49 1.12 X 4.09 4.28 2.03

IMP Wall Assembly: Installation - Support Structure - Vertical Panels
Vertical panels are installed over horizontal supports such as:

• tube steel, hot-rolled girts, or open web joists
• pre-engineered metal building girts
• hat channels, sheeting angle, or stud bridging (used with vertical steel
studs), and
• horizontal hat channels over masonry walls.
Support spacing, gauge, and depth are determined by the building

structural engineer and based on project design loads. Vertical panels
require horizontal supports to attach to wind supports meeting ASCE 7-10
minimum design loads for wind and thermal.
Important installation note

Panel layouts on the shop drawings should be drawn so that the vertical
joints of the panel do not line up with the edges of the framed openings.
Lining up the vertical joints at the penetrations does not allow proper
weather seals due to the offset interior joint configuration of the panels.

IMP Wall Assembly: Installation - Support Structure - Vertical Panels
These photos show a typical vertical panel installation. When designing with IMPs, it is important to consider the allowable
span in between the supports to ensure proper, secure installation. Vertical panel orientation provides the best vapor seal
and foam-to-foam contact without interruption, improving the thermal efficiency of the building envelope.

Installation Basics: Joint Orientation for Vertical Installation
This rendering shows the typical IMP installation with a through clip Female pockets
on left edge
screw to the structure. The installation process is progressive—it Clip and two
starts on the left and moves to the right with the male legs on the right fasteners
edge of the panel and the female pockets on the left edge. If the
panels are installed right to left, the panels must be rotated.
Once the interlocking tongue-and-groove joints are joined, a fastener Male legs on
clip with provided screws is used to attach the panel to the structure. right edge
The leading edge is always the through-fastened side of the panel.
Each IMP manufacturer has specific requirements for span and

structure mounting and can assist in designing and specifying the
proper attachment for the building project.
Left-to-right installation

Installation Basics: Engaged Joint
A standard engaged panel joint on an exterior cold storage

building must have direct foam-to-foam contact and a vapor seal.
On all cold storage construction, the vapor seal is a generous

bead of butyl caulking placed in the female groove on the warm-
side joint of the panel. In cases of washdown areas, an optional
butyl seal can be used on the interior side of the joint. Note, a
building designed to comply with USDA must have a bead of
silicone sealant along the vertical joints.

Installation Basics: Outside Corner Flush Trim
This outside corner detail illustrates the importance of the warm-

side vapor seal, which, in this case, is a sheet membrane
material applied over the panel and underneath the sheet metal
trim.
As with all cold storage detailing, foam-to-foam contact and a

thermal break are required at all intersecting panels. This detail
clearly shows the kerf cut into the interior metal skin of the
vertical panel; the joint is field-foamed with two-part expandable
foam.

Installation Basics: Roof to Wall (Exterior)
The transition from the wall to roof is one of the most critical
vapor details in cold storage design and requires great care,
especially at the thermal break. Structural members are
common obstructions in the continuous seal of the partition
panel to the exterior cooler or freezer panel. Generous
amounts of a two-part expandable foam can be applied
between the wall panel and roof insulation. In this detail, a
complete thermal break needs to be cut horizontally into the
interior metal skin of each panel.

Installation Basics: Base with Insulated Slab
This detail illustrates the IMP base condition at an insulated

freezer floor. The base must be isolated by a vapor barrier at the
mud slab and around the interior perimeter of the IMP to the top
of the curb.
The interior side of the IMP shall also have a thermal break cut
into the insulation at the section abutting the floor insulation. The
vapor barrier prevents condensation at the connections and
provides a bond breaker between the IMP and the concrete slab.

Installation Basics: Ceiling Tee
Ceiling Ts are designed to L/240 and are rated for

uniform loading based on spacing and span between
panels. The panels lie in a continuous butyl seal, and
the void created between panels must be filled by two-
part expandable foam.
The top of the assembly must be finished by capping

with a vapor barrier and metal trim. The rod should be
insulated to eliminate condensation.

Warranties
The evidence of the durability of IMPs is seen in the standard

warranties offered. Typically, IMP warranties that cover workmanship
and defects from deflection and delamination are provided by the
manufacturer, while finish warranties are available through the paint
suppliers. No interior finish is warranted due to the inability of the
manufacturer to control the application and end use, or abuse.
Please remember the exam password FREEZER. You will be required to enter it in
order to proceed with the online examination.

Testing of IMPs
Testing of IMPs is conducted in various categories including:

• fire performance per Chapter 26, Foam Plastics, of the International Building Code (IBC)
• structural performance (e.g., shear, tensile, and compression strengths, span capability)
• thermal performance (e.g., thermal values and temperature stability), and
• air, vapor, and water performance (e.g. airtightness, water absorption).
Testing is completed through various testing organizations to meet stringent industry standards set forth by:
• ASTM International
• FM Global (FM)
• Underwriters Laboratories (UL)
• American Architectural Manufacturers Association (AAMA)
• National Fire Protection Association (NFPA), and
• International Energy Conservation Code (IECC).

Case Studies

BC Tree Fruits Cooperative Okanagan Valley, British Columbia, Canada
At BC Tree Fruits Cooperative, the existing controlled atmosphere and refrigerated storage systems were antiquated and
inefficient from an energy use point of view. The facility needed major upgrades to improve the quality of the product,
reduce the building’s carbon footprint, and lower excessive maintenance costs.
IMPs, designed for controlled environments, were selected to provide an airtight envelope and to maintain the desired
concentrations of oxygen and carbon dioxide in the 23 atmosphere-controlled storage rooms. Before they undertook the
renovations, BC Tree Fruits was averaging seven months’ storage of their apples. Today, it is a different story. Now the
apples can be stored for up to a year, and the BC Tree Fruits Winfield, British Columbia, facility is one of the most modern
and up-to-date packing plants in Canada.

Urban Stead Cheese Cincinnati, Ohio, USA
Urban Stead is a food-manufacturing facility designed by Sanitary Design Industries, which provides state-of-the-art
sanitary air management and building systems for food, pharmaceutical, and agricultural production facilities. Urban Stead
is part of the growing trend of urban creameries that produce artisanal cheeses in metropolitan areas. In designing Urban
Stead, the primary focus was the building envelope. IMPs were selected for the walls and ceiling throughout the facility,
which includes a “raw room” where they receive milk, a production room, aging rooms, a packing room, and a finished-
goods cooler. The panels at Urban Stead are finished in stainless steel; the smooth finish is easier to keep clean than
panels with an embossed finish. The joints are sealed inside and out.

Urban Stead Cheese Cincinnati, Ohio, USA
IMPs gave the designer total control of the envelope, including vapor
barriers, water barriers, and sanitary finishes. Using traditional wood or
steel frame construction means that the cavity is filled with insulation,
plumbing, and electrical conduit—all of which can compromise the
envelope over time. Water pipes create condensation and increase the
risk of mold, and the risk of roaches and other insects making their
home inside the walls—a nightmare in any food-manufacturing facility.
The IMPs were chosen primarily because of their benefit to the building
envelope, but there’s an added bonus—the R-value they provide. They
have a much higher R-value than necessary at Urban Stead, which
prevents any thermal issues between rooms that operate at vastly
different temperatures; the production room is kept around 75 degrees,
the aging rooms are 50–60 degrees, and the cooler operates at 36
degrees. In the floors, the building is designed with thermal breaks
beneath the walls so there is no carryover from the slab.

WinCo Foods Phoenix, Arizona, USA
WinCo Foods had earned the reputation of providing superior products all housed in high-performing buildings. Such
facilities are critical for WinCo Foods’ success as it continues to experience strong growth in the very competitive grocery
market. The grocery chain based in Boise, Idaho, constructed an 862,711-square-foot cold storage warehouse and
distribution center in Phoenix, Arizona. IMPs were chosen to form the exterior envelope and all interior partition walls for
the building. They were also specified for an industrial-sized freezer, several coolers, the dry goods warehouse, and the
facility’s truck maintenance area. The new facility gives WinCo Foods a more economically favorable way to serve its
stores in Arizona, Southern California, and Southern Nevada.

Summary

Insulated Metal Panels (IMPs)
An IMP is composed of an insulated core material between two precoated metal skins and provides high R-values.
It features an interlocking joint that enhances airtightness performance over the service life of the building.
IMPs can be used in multiple applications and offer unique design opportunities through accessories and trims;
they’re available in wide variety of profiles, colors, and finishes. They are a factory-assembled, custom-made,
single-component system with integrated environmental control layers.
Creative Single-Component Faster Build High

Freedom System R-Value
Design Flexibility/Aesthetics Single Component Speed of Build High Performance
Profiles, finishes, colors, Factory-assembled Faster on-site installation Provides superior levels of
modules, lengths, detail components, integrated time compared to traditional thermal (R-value) and
options, and integrated environmental control layers, multipart systems airtightness performance over
accessories simplified wall design with fewer the service life of the building
trades involved

IMPs provide all four environmental control layers: water, air, vapor, and thermal.
Water Air Vapor Thermal
Controls rain and Control of air leakages Manages movement of Controls heat transfer,
groundwater intrusion, including air-transported vapor (diffusion), even maintains conditioned
protects from elements moisture without air movement interior environment
The coatings used on IMPs designed specifically for temperature-controlled environments have particular properties
suited to different environments. The corrosive factors of an internal environment are determined by the presence of
corrosive chemicals and/or microorganisms in the internal atmosphere and by the relative humidity, as well as by the
frequency of cleaning; aggressiveness of the cleaners, degreasers, and sanitizers; and the methods of cleaning.
Controlled environment IMP systems are designed for use within temperature-controlled, hygiene-safe environments,
including any facility that falls under the U.S. Food and Drug Administration (FDA) or U.S. Department of Agriculture
(USDA) guidelines.

Conclusion
If you desire AIA/CES, state licensing or CE credits for another organization,

please click on the button to commence your online examination. A score of
80% or better will allow you to print your Certificate of Completion; you may
also go to your AEC Daily Transcript to see your completed courses and
certificates.
For additional knowledge and post-seminar assistance, click on the Ask an

Expert link. ©2018 Kingspan Insulated Panels. The material contained in this course was
researched, assembled, and produced by Kingspan Insulated Panels and remains
If you have colleagues that might benefit from this seminar, please let them its property. Questions or concerns about the content of this course should be
know. Feel free to revisit the AEC Daily website to download additional directed to the program instructor. This multimedia product is the copyright of AEC
programs from the Online Learning Center. Daily.
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About the Instructor About the Sponsor Ask an Expert

Cold Storage and

Insulated Metal Panels

Kingspan Insulated Panels

Cold Storage and Controlled Environments Using Insulated Metal Panels

Presented by: Kingspan Insulated Panels

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Purpose and Learning Objectives

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How to Use This Online Learning Course

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Architectural Insulated Metal Panels (IMPs)

IMPs in Controlled Environments

Design Criteria and Installation

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Architectural Insulated Metal Panels (IMPs)

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Environmental Control Layers

Building envelopes, also known as building enclosures, are

For optimum performance, environmental separators should include:

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Environmental Control Layers

Water Air Vapor Thermal

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This detail shows the base concept of Consistent R-value

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An IMP features a tight-fitting interlocking joint that enhances

During construction, the double-lapping, interlocking labyrinth

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IMPs in Temperature-Controlled Environments

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IMPs in Temperature-Controlled Environments

The sun’s radiation hits the

Less heat is absorbed by

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IMP Insulation Core: Design Options

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IMP Insulation Core: Design Options

While assisting to reduce energy consumption and carbon emissions of

With increasing demands for products categorized as zero GWP and

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IMPs in Controlled Environments

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Attributes of IMP Systems in Controlled Environments

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Cold Storage Design with IMPs

Storage Facilities.” Note, there may also be 40 to 50 Perimeter 25 30 to 35

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Food Safety and IMP Systems

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Food Safety and IMP Coatings

The coatings on IMPs used in temperature-controlled environments

The corrosive factors of an internal environment are determined by

considered separately if they have different corrosive environments. Modular Zone

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Food Safety and IMP Coatings

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Food Safety and IMP Coatings

C1 Dry-packaged cold storage, docks, locker rooms, toilets,

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