How to Build Cold Room With Own Hands

Date: 22 December 2017

How to build walk-in coolers and freezers with own hands

Whether you're looking to solve storage needs for your business or require a large cooling chamber (from 4 cubic meters or 141 cubic feet) for residential use, building your own walk-in cooler or freezer is a practical solution. This guide will help you navigate the selection and installation processes without necessarily requiring professional help, except in specific scenarios.

 cold rooms

Understanding Cold Rooms

A cold room can store a variety of products including meat, vegetables, fruits, dairy, and more. These can be constructed independently in simpler cases, using the following methods:

  1. Purchase a Prefabricated Cold Room: This is the quickest solution. These rooms come as a kit including heat-insulating sandwich panels with polyurethane fillers, which offer easy assembly using straightforward fittings like dovetail joints or eccentric locks. Prefabricated rooms can be relocated if needed and typically include a swing door.

  2. Assemble Using Sandwich Panels: For those who prefer a hands-on approach, constructing a chamber from sandwich panels offers flexibility. You'll need to determine the number of panels based on the desired dimensions of your chamber. Panel widths vary by manufacturer but generally range from 1100 to 1200 mm. Assembly instructions, including how to secure joints and avoid thermal bridges, are usually provided by the manufacturer.

  3. Upgrade an Existing Space: The most cost-effective but labor-intensive option is converting an existing room. This involves insulating walls, ceilings, and sometimes floors with materials such as sandwich panels or sprayed polyurethane foam. Care must be taken to use insulating fasteners to prevent thermal bridges and potential condensation issues.

Installation of Refrigeration Equipment

After constructing the chamber, installing refrigeration equipment is crucial. For most DIY builders, the simplest solution is a refrigeration monoblock, which is suitable for maintaining temperatures from about 0°C to +5°C (32°F to 41°F) for coolers and -15°C to -25°C (5°F to -13°F) for freezers. These systems are self-contained and relatively easier to install but may require technical knowledge for proper setup.




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1. Prefabricated-Demountable Refrigeration Chambers: An Efficient Cold Storage Solution

Prefabricated refrigeration chambers represent the simplest and fastest method to establish a fully functional cold storage unit. These chambers are comprised of ready-to-assemble heat-insulating sandwich panels that are infused with polyurethane for superior insulation. The panels are designed to connect seamlessly through specially engineered straight and corner junctures, ensuring a tight seal and consistent internal temperatures.

The design of these chambers allows for easy dismantling, making them ideal for relocation without compromising their structural integrity or performance. Each kit includes all necessary components, including a swing door, simplifying the installation process. To get started, you simply need to determine the required volume and dimensions of the chamber and place an order with an authorized dealer.

Refrigeration Chambers

Assembly is straightforward and can usually be accomplished by 2-3 people without the need for specialized skills. There are two primary types of prefabricated chambers, differentiated by their panel connection systems:

  1. Profile Plastic Chambers: These utilize spike-groove joints, commonly referred to as 'dovetail fastening.' This type of connection is less expensive but requires the application of sealants at the joints to ensure proper insulation. Due to the less rigid nature of the plastic fastenings, these chambers are generally smaller, typically not exceeding 2-3 meters in width or length.

  2. Lock Chambers: These feature an eccentric lock mechanism integrated into the sandwich panels, which provides a robust and durable connection capable of withstanding multiple assemblies and disassemblies. This design ensures a more stable structure and is better suited for larger installations.

Although the cost of prefabricated chambers might be slightly higher compared to other options, they offer a quick and effective solution to setting up a quality cold storage space. These chambers are designed to avoid thermal bridges, thereby enhancing energy efficiency and maintaining consistent cooling. For businesses and individuals needing a reliable and quick-to-assemble refrigeration solution, prefabricated chambers provide an excellent choice.


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  2. Fitting of Sandwich Panels for DIY Cold Storage Chambers

Building your own cold storage chamber using sandwich panels offers flexibility and customization to suit your specific needs. Here’s a detailed guide on how to proceed with the assembly of sandwich panels to create an efficient and durable cold storage space.

Calculating Requirements

  1. Panel Dimensions: Determine the number of panels and their dimensions based on the intended size of your cold storage chamber. Panel widths typically range from 1100 to 1200 mm, depending on the manufacturer. You will need to calculate both the total number of panels and their required lengths to complete your chamber.

  2. Documentation: Refer to the manufacturer's documentation for specific instructions on the assembly process, particularly how to secure straight and angled joints. This information is crucial to ensure a proper and safe assembly.


Panels


Assembly Process

  1. Avoiding Thermal Bridges: A critical aspect of assembling sandwich panels is preventing the formation of thermal bridges at the joints, where the inner and outer metal shells of the panels meet. To avoid these:

    • Rupture Creation: Make a slit in the inner metal skin at the corner joints where the panel "exits" to the exterior of the chamber. This slit helps break the continuity of the metal, thereby preventing heat transfer through the metal.
    • Partitioning Multi-Section Chambers: For chambers with different temperature zones, it's necessary to cut through the inner metal layers at the installation site of each partition, effectively isolating different sections thermally.
  2. Floor Insulation: In chambers where the storage temperature is above zero degrees Celsius, it's common to leave the floor without thermal insulation. This approach facilitates the movement of loading equipment like rollers and trolleys. However, this also means that refrigeration systems need about 20% more capacity, leading to increased energy consumption.


  Panels

Finishing the Installation

  1. Sealing and Insulation: Purchase finishing accessories such as battens and angle profiles to secure the corner joints of the panels. Sealants are essential to ensure air-tightness, enhancing the chamber’s overall thermal efficiency.

  2. Specialized Doors: Opt for a special refrigeration door with thermal insulation, typically made from polyurethane foam, to maintain consistent internal temperatures. Some panel manufacturers offer doors specifically designed for these purposes, or you may source them from specialists in refrigeration door production.

By following these guidelines, you can create a custom cold storage chamber that meets your specific needs while ensuring optimal operational efficiency and energy conservation. This DIY project requires careful planning and precision but can be highly rewarding and cost-effective.






3. Reconstruction of a Premise into a Refrigerated Chamber

Reconstructing an existing warehouse or room into a refrigerated chamber is often seen as a cost-effective solution, though it may not always yield the most profitable outcomes in the long run due to potential inefficiencies and compliance issues. Here’s a breakdown of how to approach this process:

Thermal Insulation Methods

  1. Using Sandwich Panels: The preferred method involves applying polyurethane foam sandwich panels to the walls and ceiling. These panels, discussed in previous sections, provide excellent insulation and are relatively easy to install with appropriate fasteners.

  2. Choice of Fasteners: Metal fasteners, commonly used in such installations, can create thermal bridges—areas where heat can transfer, leading to condensation and potential rust at the fastening points. To avoid this, it's advisable to use thermal-insulating fasteners, such as polyamide studs, though they are more costly and difficult to work with.

  3. Alternative Insulation Materials:

    • Expanded Polystyrene Boards (PBP): Lightweight and easy to install, these boards are another option but may not offer the same level of insulation as sandwich panels.
    • Urethane-Foam Mats: These provide insulation without metal sheathing, reducing the risk of thermal bridges but may require additional structural support.
    • Spray Foam Insulation: Applying polyurethane foam directly to walls and ceilings offers comprehensive coverage but needs to be covered with metal sheathing to meet mechanical protection and hygienic standards.

Considerations and Challenges

  1. Labor Intensity: The process of applying these materials and ensuring proper insulation can be laborious. The end result, while cost-effective, may not always meet the high standards required for commercial refrigeration in terms of thermal efficiency and moisture control.

  2. Compliance and Quality: Insulating existing structures, while economical, may not always comply with stringent hygienic requirements for food storage. This method could lead to issues with inspection bodies if not executed correctly.

  3. Selecting the Right Premise: When converting a space, consider the specific requirements for the stored products, such as temperature and humidity control. The chosen premise must be suitable for adaptation to ensure that it can maintain the necessary conditions without excessive energy consumption.

Final Thoughts

While retrofitting an existing room can be less expensive upfront, it requires careful consideration of materials, installation techniques, and ongoing compliance with safety and hygiene standards. For those seeking a more straightforward and reliable solution, prefabricated panels are recommended despite the higher initial cost. This approach not only simplifies the installation process but also provides better long-term value through enhanced energy efficiency and compliance with regulatory standards.


Read more about cold rooms for flowers and cold-storage chamber for meat products in next our articles.

Tips and Considerations
  • Quality of Materials: Choose high-quality insulating materials to ensure efficient temperature control and durability of your cold room.
  • Sealing and Insulation: Proper sealing and insulation are critical to prevent air leaks and maintain consistent temperatures.
  • Regulatory Compliance: Ensure your construction meets local building codes and food storage regulations, especially if you're building for commercial purposes.


Additional Resources

  • YouTube Tutorials: For visual learners, consider following channels like "Refrigeration Industry" on YouTube, which offers step-by-step guides and updates on the latest in refrigeration technology.
  • Refrigeration Equipment Suppliers: For those looking to buy refrigeration systems, our online directory can help you find reliable suppliers and brands.

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