Farm Structures

Order No. 306.300-2

October 1989
Agdex: 736

LAYOUT AND DESIGN OF

REFRIGERATED STORAGES
There are a number of questions that have to be the containers which will be stored and for the air
asked when planning an on-farm refrigerated circulation system used within the cooler.
storage structure. These would include such items
as location, accessibility, size, cooling capacity, A number of methods of construction can be
construction techniques, expandability, cost and employed and will depend on the size of the
returns. facility, whether it will be free standing or in an
existing building and who will build it. The most
On-farm cold storage can be either free standing, common methods are:
that is a building of its own, or built into an
• steel construction – usually larger facilities
existing structure. It is of prime importance that
• masonry – medium size facilities
the facilities are located so that it is easily
accessible for bringing produce into the structure • wood frame – small facilities
and for taking it out. If large volumes are
anticipated, truck loading should be considered. Doors
Additional building space may be required for Special doors are required and these can be bought
receiving, grading, processing, packing and ready-made or U-built. Ensure manufacturer’s size
loading out. The building site should be well is determined prior to framing when purchasing
drained. It has been stated that a normal operation manufactured doors. Special hinges, door openers,
will expand facilities as many as four times in any safety bars, sealing strips and insulation is
generation and, therefore, expansion capabilities required for the doors. Four feet by seven feet is
should be planned for in the initial layout. recommended as an absolute minimum size.
Obviously, larger sizes will be required for forklift
When forklifts are used in the storage facility, operations.
floor construction should take into account these
concentrated loads and well compacted sub-grades
Vapour Barriers
should be prepared prior to pouring any concrete.
It is of prime importance that the vapour barrier be
A room that is square-shaped is most economical placed on the exterior or warm side of the
in that surface areas per total volume are insulation. Normal house construction has a
minimized. This will reduce heat losses and vapour barrier toward the inside of the house
reduce construction costs. Adequate space must be which is opposite to the requirements of
provided in the room for the evaporator unit as refrigerated spaces. The vapour barrier must
well as for maneuverability of the produce in the encompass the whole cold storage structure and
cooler. The cooler should be sized specifically for all joints must be well sealed. (See Engineering
Plan 330.10 “Cold Storage Wall Sections”.

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Insulation
Insulation used in these storages can be Based on the actual construction, an “R” value
polyurethane, styrofoam, fiberglass batts, any (insulation factor) is calculated. See Table 1 for
other good insulating material or any combination thermal properties of selected insulating and
of the above. Walls should have a minimum “R” building materials. Typical “R” calculations are
value (insulation factor) of 20, ceilings of 30 and given:
floors and foundations of 10.

Wall “R” Factor

Outside air 0.28
5-1/2” fiberglass 18.26
1” rigid insulation 5.26
1/2” plywood 0.63
Inside air 0.17
Total “R” for wall 24.60 (hr ft2 oF/BTU)

Ceiling
Outside air 0.28
5-1/2” fiberglass 18.26
2” rigid insulation 10.52
½” plywood 0.63
Inside air 0.17
Total “R” for ceiling 29.86 (hr ft2 oF/BTU)

Floor and Foundations “R” Factor

2” rigid insulation 10.52
4” concrete (6” foundation) 0.44
Inside air 0.17
Total “R” for floor 11.12 (hr ft2 oF/BTU)

Note: For floors, assume ground temperature to be 45oF.

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Table 1

Thermal Properties of Selected Insulating and Building Materials

“R” Factor “R” Factor

British Units Metric1 Units
Material (hr ft2oF/BTU) (m2oK)/W

Insulation

Fiberglass batts2 3.32/inch .230/cm

Fiberglass, loose 2.55/inch .177/cm
Fiberglass, board 4.00/inch .277/cm
Cellular glass (Foamglas) 2.86/inch .198/cm
Styrofoam, extruded 5.26/inch .346/cm
Styrofoam, beadboard3 4.17/inch .289/cm
Polyurethane, board 6.25/inch .433/cm
Polyurethane, foamed-in-place 6.25/inch .433/cm
Polyisocyanurate, board 7.04/inch .488/cm

Building Materials

Fir plywood 1.25/inch .087/cm

Fiberboard sheathing1/2” 1.32 .233
Particle board 1/2” (Aspenite) 0.92 .162
Gypsum board (5/8”) 0.56 .099
Concrete, cast 0.11/inch .008/cm
Concrete block 8” 1.11 .195
Concrete block 12” 1.28 .225
Glass, single pane 0.10 .018

Fire Coatings for Foam

Perlite Gypsum Plaster (1/2”) 0.33 .058

Vermiculite Gypsum Plaster (1/2”) 0.30 .053
Fire Retardant Cellulose (1”) 4.00 .71

Air Film and Air Gaps

Air Film, outside summer or inside heated 0.28 .044

Air Film, outside winter or inside cold storage 0.17 .030
1 inch or greater air gap (average value) 0.72 .127
1
Metric Conversion Factors: ((hr ft2oF)/BTU) * 0.176 = (m2oK)/W
inches * 2.54 = cm
2
Unfaced, average value for several types
3
1.5 lb/ft3 (0.024g/cc) density

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Layout Rooms should always be stacked with the pallet
bin runners oriented in the same direction as the
The storage room layout and refrigeration system evaporator discharge. It is essential that the bins
should be designed for maximum temperature be properly oriented to provide air distribution
pull-down efficiency. Optimum field heat removal channels for faster cooling. If the pallet runners
is obtained in a system having both adequate are properly aligned, cooling air can absorb heat
refrigeration capacity and an efficient air from the top and bottom bin surfaces more
distribution system. effectively. It is important to use identical pallet
bins in each row to ensure that the runner
The cooling air from the evaporators must be openings are continuous from the front to the back
delivered in sufficient quantity and at proper of the room.
velocity to provide effective cooling throughout
the storage volume. Ceiling mounted, direct throw It is desirable to leave a four to six inch spacing
evaporators must be sized according to the cooling between stacks of bins to promote heat transfer
load, be equipped with fans of correct capacity to along the sides of the containers. Bin spacing is
move air throughout the storage, and be positioned easily managed if the bin row location is marked
in the proper location to facilitate maximum air on the floor of the storage with paint. The stacking
movement. Better air distribution is obtained with patterns for new storage rooms should be
several small evaporators located along one wall established so that the bin orientation and spacing,
than a single, large unit of equivalent capacity relative to the refrigeration system, is known
located in the centre of the same wall. Coils must before construction takes place. This will ensure
be kept free of ice to ensure efficient heat optimum use of floor space and refrigeration
exchange and proper air velocity. capacity during pull-down.

Loading and Stacking A minimum of eight to ten inches should be left

Room loading and stacking patterns have a between the pallet bin stack and the wall,
profound effect upon air distribution and the rate downstream from the evaporator. This space is
of cooling. Ideally, the warm product should be necessary to ensure that all of the cooling air may
spread out in the storage with the warmest pass down behind the stacks on the far wall,
commodity exposed to the coldest portion of the circulate uniformly back through the produce and
air stream. This may not always be possible due to be picked up by the evaporator at the near wall. A
separation of product lots and the configuration of six to eight inch space is usually left between the
the room, but every attempt should be made to outside bins and the side walls. A curb is usually
distribute warm products in the room during secured to the floor around the perimeter of the
loading. Stacking the first hot product directly store room to guarantee the bin to wall spacing
underneath the evaporator helps to ensure that the and to protect the wall insulation from damage by
warmest product is in contact with the coldest air bins stacked near the wall.
as the evaporator discharge stream is moved over
the top and back through the stacks of newly In summary, the following clearances are
loaded produce. recommended:

Walls - 6-8 inches

Ceiling - 24 inches
Between pallets - 4-6 inches

FOR FURTHER INFORMATION CONTACT RESOURCE MANAGEMENT BRANCH

Bert van Dalfsen, Mechanization Engineer (Written by: Erich Schulz, Engineering Technologist) Ministry of Agriculture and Food
Phone: (604) 556-3109 1767 Angus Campbell Road
Email: [email protected] Abbotsford, BC V3G 2M3

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