Master-Bilt® Refrigeration News & Product Information


Refrigerated Warehouses 101

Updated 8-29-23

Refrigerated warehouses have a ton of uses, from storing frozen foods to housing testing facilities. If you’re gearing up to construct one from scratch, it’s all about starting off with a solid plan. Most people picture a refrigerated warehouse as a gigantic walk-in cooler, and the initial design process looks quite similar.

First things first: you’ve got to nail down the basics. That means figuring out the right size, temperature settings, number of compartments, and cooling capacity. Once you’ve got those fundamentals locked in, it’s time to consider some other important factors. Think loading docks, roof support, properly sized doors and super-durable flooring.

And don’t forget about the local rules and regulations. There might be building codes to follow depending on where you’re located. Some areas might require your structure to be earthquake-proof, while others might be more concerned about snow loads on the roof. Building a cold storage warehouse involves juggling a lot of details, and this article is here to give you a solid starting point. Need more info? Reach out to us at 800-647-1284. We’re here to help you out!

Wall And Ceiling Panels

Typical polyurethane foamed-in-place panels, which fit together by cam-locks, are four inches thick and provide excellent energy efficiency. Five-inch and six-inch panels provide even greater insulation efficiency and structural support. Additionally, there are numerous interior and exterior metal finish options to match your design scheme or durability requirements.

Refrigerated Warehouse Floors

Special consideration must be taken when specifying a refrigerated warehouse floor, especially if it’s a freezer. The design can get complex, usually involving a slab of polyurethane insulation sandwiched between a top layer of concrete and a lower concrete subfloor. Beneath the subfloor there’s frequently a gravel bed measuring a foot deep. A treated wooden thermal break lines the perimeter of the floor to prevent the transfer of cold air through the concrete. Plastic visqueen vapor barriers are also installed between the insulation slab and the concrete subfloor to block moisture coming upward from the ground.

Underfloor heating is also necessary as a shield against the upward expansion of frozen water in the ground beneath the sub slab. This heating, or defrosting, is accomplished in several ways. One of the most popular is to install PVC piping in the floor allowing warmer ambient air to act as a defroster. Other ways include electric heating and glycol pumping.

Click or tap here to see a detail drawing of a typical insulated slab floor with panels on sub slab.

Here’s a detail of a typical warehouse insulated slab with panels on a finished floor.

Refrigerated Warehouse Ceilings And Roofs

Depending on the size, location and complexity of a warehouse, there are different ways to design the roof or ceiling.

If the structure is housed within a larger building, a self-supporting ceiling could be the best choice. With this ceiling type, walk-in panels are connected to overhead steel beams by self-support clips. Pallet racks inside the structure may also be used to support roof panels.

Pallet racks can be used to support a warehouse roof.

Because most warehouses are large, walk-in ceiling panels require extra support to span the greater distances. That support is provided by a suspension ceiling with structural steel angles connected to the building roof by steel rods and to the ceiling panels by support clips.

Suspension ceilings provide extra support to span greater distances in indoor warehouses.

In outdoor refrigerated warehouses, walk-in ceiling panels are bolted to horizontal steel beams beneath them. The beams are supported by columns to which the wall panels are attached. Add protection to the roof and the inside contents with optional galvalume or membrane finishes.

Refrigerated Warehouse Docks And Doors

Loading docks are an absolute necessity if the refrigerated warehouse is intended to function as a distribution center. The precise number of docks required will naturally hinge on the available space and the volume of shipments anticipated. The installation of docks introduces additional considerations, including the incorporation of weather seals and vinyl curtains.

Weather seals play a crucial role by being positioned on the exterior of the loading dock. Their purpose is to create a secure seal along the perimeter of a trailer, preventing the escape of cold air from the interior. Similarly, vinyl curtains are employed to cover doors and entrances, effectively obstructing the infiltration of warmer air.

Loading docks with weather seals are a necessity in many warehouses.

Warehouses usually require doors that are large enough for forklifts and other vehicles to pass through. Depending on budget and personal preference, there are a wide variety of choices including manual or electric sliding doors, bi-parting doors and overhead sectional and vertical lift doors.

Warehouses usually require doors that are large enough for forklifts and other vehicles to pass through.

This article has addressed several key considerations regarding refrigerated warehouses. However, as previously mentioned, there are numerous other factors to take into account. Given the intricacies of the construction process, it is advisable to seek out one supplier who can offer not only design assistance but also provide essential components like panels and refrigeration systems. Having a single source supplier can streamline the process and ensure a cohesive approach to building the facility.