Basic factors in cold store design W.K. Hemmings
Principaux facteurs de la conception des entrep6ts frigorifiques On passe en revue les iddes modernes concernant la
conception et la construction des entrep6ts frigorifiques. On examine le choix du type de construction et de pamneaux isolants ainsi que les probl~mes de la construction des planchers et du gel des sols. On passe en revue les caract~ristiques de I'installation parmi lesquelles la mise en place des portes et desfrigorig~res. On insiste sur la n~cessit~ d'une /imitation de pression.
Modern practice in cold store design and construction is reviewed. The choice of structure and refrigeration panelling is discussed together with the
Layout features including the positioning of doors and coolers are reviewed. The need for pressure relief is emphasized.
problems of floor construction and frost heave. A student, writing a thesis on cold stores, made a very telling observation when he wrote: "My first discovery was that cold store design comes from trade-based origins, many architects knowing very little on this subject, and many insulation contractors being reluctant to release information'. This article is intended to go some way towards correcting that omission. The average percentage cost of each trade within a cold store is as follows:Building work Steelwork and cladding Plant and electrics Insulation
30% 18% 21% 31%
Hence insulated panel manufacture is one of the most important components in a cold store and it is, therefore, worth looking at materials and methods of manufacture in some detail. Nowadays, factory made insulation panels are delivered to the site complete with vapour barrier and internal cladding thus reducing site work to a minimum ~. In the majority of cases the external finish to both wall and ceiling panels is galvanized mild steel sheeting, with an internal finish of w h i l e ~ or acrylic paint on galvanized mild steel sheet. This type of sheeting gives a 100% vapour barrier on both sides of the panel, it can be obtained in sheet or coil form, but for cold store panels it is more economically manageable in coil form. The coils are processed through a series of forming machines, which straighten, guillotine, punch and notch, rib and bend edges, producing an accurate, reasonably rigid metal tray (see Fig. 1 ). / h e author is chairman of C. Hemmings and Co. Ltd, Merseyside, UK Paper received 1 October 1978
Volume 2 Number 2 March 1979
Fig. 1 Automatic sheet metal fabrication line Fig. 1 ChaFne de fabrication automatique de t61es m#talhques
Another, less accurate, method is to cut sheets from a coil, usually going through a straightener, but without any forming. These sheets are then bonded onto the insulation. Pre-formed, profiled metal sheets can also be used but they are difficult to handle. There are two main insulants - polystyrene and rigid polyurethane. The latter is preferred because of its superior properties and strength. Polyurethane can be made into composite panels in a number of ways. The most efficient and economical is to pressure-foam it between metal sheets in either horizontal or vertical presses. There is no double handling of material or cutting of slab which can result in some loss of thermal efficiency. It is also self-bonding and will mould to the shape of the jig. Other methods include the continuous lamination of polyurethane, usually onto paper with two laminates bonded afterwards, and possibly incorporating a timber frame.
0 1 4 0 - 7 0 0 7 / 7 9 / 0 2 0 0 7 1 -04 $ 0 2 . 0 0 © 1979 IPC Business Press Ltd.
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all the client's requirements have been met and soil conditions and water tables t h o r o u g h l y checked. Site work commences with the levelling of ground, laying of foundations and the erection of the supporting structure. In the latter c o n n e c t i o n it is worth noting that lattice trusses are more stable than portals and concrete columns are worth considering from the fire and maintenance point of view,
Fig. 2 6 m Horizontal presses for the manufacture of rigid polyurethane insulated oanels Fig. 2 Presse hor~zontale de 6 m p o u r la fabrication de panneaux ~solants en mousse de polyur#thane ngide
Polystyrene is fabricated into panels from slabstock by bonding to metal sheets. This can be done by the simple method of bench lay-up and roller press or the more sophisticated method of a c o n t i n u o u s lamination process. Polyurethane slabstock can also be used in both of these laminating processes, but loses some of its natural advantages. The length of panel manufactured is dependent upon the size of press employed or, in the case of the c o n t i n u o u s laminating processes, the maximum handleable length. The present requirement for cold stores is up to five or six pallets high or approximately 12 m. Also, anything more than 12 m becomes difficult to transport and erect.
An important primary decision in the selection of a construction system is whether the panels should be erected inside or outside the main structure. If erected inside, weather protection during erection is better, site access is easier, roof space can be vented and inspected, and the appearance externally and internally is cleaner. When the panels are erected outside the overall height of the cold store can be lower and the coolers can be mounted between the trusses. In both cases it is recommended to provide an external sheet cladding for added protection and thermal efficiency. Heater mats will be discussed in more detail later, but these will have been laid before the insulation panels arrive on site. There are three basic methods of panel erection - by block and tackle (wall panels only), for k lift truck or flying carpet machine (see Fig. 3).
The object is to design and manufacture a panel w h i c h is as accurate as technically feasible with maximum production completed in the factory so that site work is reduced to a minimum. That is w h y the jointing method is preferably formed in the press, panel locks are foamed in with the polyurethane process and panels are cleaned and gasketed prior to despatch. Other methods of jointing include foam-on-site joints, tongue and groove or rebate joints. Before considering methods of construction, it is important to distinguish between coldrooms and cold stores. The definition of a coldroom is a free-standing structure within an existing building w h i c h takes no support from the s u r r o u n d i n g building. Sizes are usually,up to 1 7 0 0 m 3, operating in a temperature range of -29°C to 6°C. The definition of a cold store is a building of steel, concrete or brick, (or a c o m b i n a t i o n of these) to w h i c h are affixed insulated panels. Sizes are u s u a l l y f r o m 1 7 0 0 m 3 upwards, and these also operate in a temperature range o f - 29°C to 6°C. A good check list on coldstore design has been written and published by the International Institute of Refrigeration called 'Guide to Refrigerated Storage '2 and this can be recommended for further reading. It will be assumed that a site has been carefully selected (nowadays usually near a motorway) and
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Fig. 3 Cold store wall panels being erected with the assistance of a 'flying carpet' Fig. 3 Panneaux m u r a u x p o u r entrep6ts f r l g o n h q u e s en cours d'/nstal/atlon a ~'aide d'un "tapls vo/ant"
International Journal of Refrigeration
tailboard loading with dock levellers and a cantilevered canopy. In this method the goods are moved in and out of the cold store by fork lift truck and loaded and unloaded into and out of the vehicles by hand or electric pallet truck. Depth of the loading dock is usually 7.5 to 8.0 m and the height 1.4 m. Height to the underside of the canopy is usually 4.8 m. Protection of the front edge of the loading dock is essential.
Fig. 4
Cooled loading dock
Fig. 4 Qum de chargement refrotd~
Fixing the panels to the steelwork is accomplished by one of the following methods: joggle clip and bolt into hidden fixing within the panel; clamp over side rail; coachscrew and joggle; bolts through top hat sections into nylon candle; or, nylon or steel bolt through panel. The floor insulation and finish must have high load bearing properties, be waterproof and offer minimum shrinkage. Vapour barriers are usually polythene or bitumen-coated polythene. Quality and accuracy of finish is critical - it is very difficult to repair afterwards and tilting will occur if the floor is not level. Expansion and contraction joints have been almost eliminated these days and mono-concrete or granolithic is the most commonly used substance, although 30 N concrete is being increasingly considered. Internal columns must be insulated and preferably fitted with heater pads. Kerbs are fitted to keep pallets away from the walls and pallet areas and passageways lined. For cold stores under 6m in height, lighting usually consists of twin 1.5 m It fluorescent. Mercury vapour is used for heights over 6 m and high pressure sodium over 7.5 m. Each application must be considered individually as there are many factors to take into account even on this one item, for example cost, type of loading and intensity required. With the development of fan design over recent years, it is debatable whether any ducting, trunking or false ceilings are required. Costs are certainly reduced if they can be eliminated.
Another item to be considered is the type of storage required. This can be pallet cage stacking, usually to a maximum of five or six high, or racking to about the same internal heights using pallet bases only. As turnover of stock in a cold store increases, more expenditure on mechanical handling equipment can be justified. The ultimate is a fully mechanised system of which there are nowa number in operation, but a turnover of at least twenty times per year is required before it should be considered 1. To return to the necessity for heater mats, the ground upon which the cold store stands experiences a small but continuous loss of heat with only a limited amount replaced from outside the store. Towards the middle of the store the only replacement is from deeper soil. Sooner or later the upper levels reach freezing point and this gradually penetrates deeper and deeper 3. Any water in the soil turns to ice which expands and frost heave starts. Slowly it gets larger and larger, lifting the floor into a humped shape and eventually, if allowed to continue, pushing out walls and distorting columns. On one particular design itwas calculated that 1 m of cork insulation would be required to avoid the use of a heater mat, and if no precaution was taken the frost could penetrate to a depth of 6 m. Various methods of solving the problem were tried during the 1950's, starting with air bricks or earthenware pipes laid beneath the sub-floor and assuming a free flow of air or forcing warm air through. In both cases installation was quite expensive and clogging could easily occur. Elevated floor slabs were tried next. It is a good solution if tail-board loading is required, but it is
If trouble is to be avoided it is wise to site coolers away from door openings, otherwise icing-up takes place. The fans should also blow the short way of the cold store. Selection of door openings and airlocks will depend on the type of storage and loading and whether the cold store is to be used by a manufacturer or a distributor, but all should be kept to a minimum clear opening, and be well protected. Escape doors also have to be provided at the opposite end of gangways to main doors (see Fig. 4). Types of loading bays also vary. One system uses
Volume 2 Number 2 March 1979
Fig. 5
External view of a modern cold store complex
Fig. 5 Vue exteneure d'un comp/exe d'entreposage frlgorlhque moderne
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expensive and, of course, the strength has to be increased as cold stores get higher. Pyrotenex wiring was tried but moisture penetrated to the inner core and rendered it useless. Next came piping with a glycol (anti freeze) solution circulating. Initially it was expensive to install, required constant maintenance and was very prone to leaks, but with further development, it is again becoming a proposition. The problem was eventually solved around 1 9 5 5 by means of a low voltage system, electrically operated using heating elements of robust stainless steel - the 'heater mat'. It is quick and easy to lay on top of site concrete, can be easily checked and has successfully stood the test of time. However, with the increase in electricity prices, it is becoming expensive to run. In summary, the elevated floor slab, the low voltage system and the glycol piping system are the three which are mainly chosen today. The choice will depend upon the overall requirements of the client. Another problem which has arisen in recent years concerns pressure changes in coldrooms and cold stores. Evidence of this came with the introduction of modular coldrooms and with improved jointing methods. The materials and joints on previous coldrooms allowed air to escape and be drawn in. The metal surfaces and jointing on the new coldrooms did not. Reports were received of loud noises similar to thunderclaps, doors were opening by themselves, and finally ceiling panels were jumping into the air or sagging into the coldroom. Eventually, these phenomena were traced to the influence of pressure changes. Pressure increase occurs immediately after a defrost cycle, when the cooler fans start up. The cold air in the room, which is at atmospheric pressure, is joined by the relatively warm air from the cooler area, resulting in an immediate pressure increase to above atmospheric. Consequently, it will find the weakest area to escape through, be it door or panel.
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Pressure decrease occurs when the coldroom door is opened and allows dense cold air to flow out at the bottom (sometimes seen as a mist) and warm air to flow in at the top. The door is then closed, the coolers reduce the warm air temperature very rapidly, thus making it more dense and taking up less space. This creates a partial vacuum, which shows up as a reduction in pressure to below atmospheric. Outside pressure tries to balance with the pressure inside and forces its way through the line of least resistance. The remedy is a two-way valve. Door wiper gaskets may be used, but some companies insert valves in the wall or ceiling. Either way, with the increasing use of hermetically sealed cold store doors and improved jointing systems, a system for counteracting these pressure changes is essential.
References 1 Persson, P.O., Jacobson, L. Apphcahon of modern techniques to cold store construction, Proc Inst Refrign 65 (1968-9) 43 2 IIR Guide to refrigerated storage, International Institute of Refrigeration Publication (1975) Paris 3 Morphew, A.E.B., Jones, A.J. The design and construction of large cold stores, Proc Inst Refrign63(1966-7) 1 In the early 1960's he introduced rigid polyurethane technology into the company. This not only changed the design concept of the products, but also allowed rapid expansion of the business.
Keith Hemmingswas born in Liverpool, UK, in 1934. He was educated at Liverpool College and then successfully completed a four year Higher National Diploma at the College of Building, Liverpool. After two years' National Service he entered the family business, manufacturing cold rooms and cabinets.
By 1970 the company had outgrown its original, already extended factory and a larger one was built at Whiston. Today, as well as being Chairman of the parent company, he is also Chairman of the three other companies in the Group. involving the manufacture of insulated doors, the operation of Licence Agreements abroad and the design and manufacture of cold stores.
International Journal of Refrigeration