FEATURES OF KOOL STAR'S HD SPEC LINE COOLERS & FREEZERS:
- 4", 5 or 5 ½ Thick KOOL STAR prefabricated modular
- 34"x78" flush fiberglass reinforced plastic door jamb
and door perimeter.
- Snap-in magnetic door gaskets.
- Kason #1256 cam lift hinges.
- Kason #1229C keyed door latch.
- Pre wired switch and pilot light and mounted vapor proof
- Solar digital thermometer.
- Wall closures and cove base included.
- Heated air vent and 4 sided door heater cable. (freezer
Cooler and Freezer Specifications
KOOL STAR walk-in coolers and freezers provided under
this specification, related provisions and drawings shall be
of prefabricated, modular design and construction. This
design shall allow for accurate and convenient field
assembly which will facilitate future enlargement or
The walk-in cooler and freezer manufacturer shall provide
and submit: product data; shop drawing plans, elevations and
details; rough-in drawings; cut sheets of buyout
accessories; installation and maintenance manuals with
copies of all warranties.
The responsibility of Kool Star, FSEC, KES, GC and other
trades vary from project to project. The ultimate
responsible party is determined by purchase order and
contract documents. Kool Star showing a responsibility in
specification or drawing details, or by others, or other
then Kool Star or similar wording does not dictate actual
- Modular Panel Fabrication:
The prefabricated, insulated panels
shall be of modular design with standard sizing to be
interchangeable in the field. Modular panels shall be 100%
foamed in place, 4-inch thick urethane insulation core, without
any wood or metal frame members. Also available in 5 and 5
½-inch thick urethane insulation core meeting the same
specifications as the 4-inch. Interior and exterior Die Formed
Sheet Metal Panels; fully adhered to urethane core. Perimeter of
sheet metal facings shall be flanged Ύ inch. Corner panels shall
be matching one-piece construction, including NSF radius at all
inside vertical corners, stacking of corners panels with less
then 30 feet in height shall not be allowed. Partition panels
shall be matching construction and finish. Intersection of wall
and partition panels shall be accomplished with T shaped
panels, matching corner panel constriction. Panel joints shall
be sealed with NSF Listed PVC gasket at interior and exterior
panel edges, maintaining continuity.
Lateral alignment of adjoining panels shall be provided for by
continuous urethane tongue and groove mating edges with a
minimum ½ profile. Panels shall be coupled by steel cam action
locks, foamed in place, maximum 40 centers. Section lock ports
shall be finished with PVC snap-in-buttons. Maximum deflection
of ceiling panels shall not exceed L/240 of the span under a
loading of 15 pounds per square foot. If the ceiling spans
require a support system, the contractor shall submit details
and structural calculations demonstrating conformance with
Each prefabricated panel shall be
"Foamed-in-Place" (injected) with U.L. Listed, Class 1 urethane
foam insulation which has a flame spread rating less than 25 and
smoke density less than 450 when tested in accordance to ASTM
E84 (UL 723). The thermal conductivity or "K" factor of the
insulation shall be 0.12 BTU/hr./ft squared per degree
Fahrenheit / inch of thickness. Overall panel thickness shall be
4". (5 and 5-1/2" thickness available) Foam insulation shall be
dimensionally stable from -100 degrees Fahrenheit to +200
- Metal Finishes:
Prefabricated panel exterior and
interior metal finishes may be specified one or a combination of
the following (other finishes available on request):
- 26 Ga. stucco embossed galvalum
- 26 Ga. stucco embossed galvanized steel
- 26 Ga. stucco embossed baked white enamel on galvanized
- 24 Ga. smooth baked white enamel on galvanized steel.
- .032 stucco embossed aluminum.
- .040 stucco embossed aluminum.
- 22 Ga. to 18 Ga. stainless steel.
- 16 Ga. No. 2 finish stainless steel. (for floor only)
- .10 smooth aluminum with nonskid strips or aluminum
tread plate. (for floor only)
- Floor Construction: (select one):
Floorless: Finished floor and/or
concrete slab provided by the General Contractor or others. Wall
panels shall be anchored to building with concealed continuous
16 gauge galvanized steel floor track anchored to sub-floor with
drive pins, 24 inches O.C. Wall panels shall be sealed to
building floor with continuous bead of sealant. This floor
application is recommended for use only with walk-in cooler
applications at temperature above freezing and installed at
grade, no space or basement below the floor.
airspace is required between building wall and walk-in to allow
for air flow and building variance. Optional vinyl screed is
available with this construction style. If tile exceeding 3/8
thickness is to be installed after installation of walk-in
allowances can be made in height of walk-in door opening. Advise
the walk-in designer of this condition.
Panels shall be of similar construction to
the other panels with a fully formed NSF interior radius and
stamped corners. Floor panels to be a FULL 4 thick insulation
at wearing surface. Floor panels shall include an interior cove
to transition the floor to wall junction, this cove will require
the perimeter of the floor to be 4 ½ off finished floor. Floor
panels shall be designed for foot traffic as a standard, and to
withstand a uniformly distributed weight load of 600 pounds per
square foot. Wall panels shall be set in a continuous groove of
floor panels and attached to the floor panels with cam locks.
C. Reinforced prefabricated floor:
Where floors will be subject to more then 600 pounds of
uniformly distributed weight per square foot, additional
reinforcement is required. Depending on the weight requirement,
the reinforcement will include a thicker metal provided for
wearing surface, plywood underlayment, non-wood, non-conductive
structural members within the floor or a combination of some or
all of the above. Advise the walk-in designer of requirements
and conditions of the use of the walk-in and reinforced floor.
insulated floor is provided in 4 recess, wall panels shall be
coupled by steel cam action locks, foamed in place, maximum 40
centers. Section lock ports shall be finished with PVC
snap-in-buttons. Floor shall of same basic construction as wall
panels. Modular panels shall be 100% foamed in place, full
4-inch thick urethane insulation core, without any wood or metal
frame members. Floor panels to include an interior cove to
transition the floor to wall junction, and shall be manufactured
as part of floor panel. This cove will require the perimeter of
the freezer floor area to be 4 ½ off recess floor, and ½ above
finished floor. A stainless steel threshold to be provided for
Prefabricated floor installed in
recess: Prefabricated floor panels shall be constructed the same
as the prefabricated floor on finished floor. When
grout or tile is installed on wearing surface of prefabricated
floor, tolerance in the entry door opening shall be allowed for
door clearance. Advise the walk-in designer of this condition.
E. Insulated concrete slab
wall in recess: FSEC shall provide a sub floor
membrane of Asphalt emulsion (ASTM D1187 clay type) applied to
clean, smooth concrete sub-floor. Coordinate depth of depression
with General Contractor. Cover with 6-mil polyethylene sheeting
extending to full size of pit. 20 wide rolls shall be utilized
to minimize seams, when seams are required; joints shall be
lapped 6 inches minimum. Sub-floor membrane shall continue up
the edge of the depression above the finished floor level. Kool
Star wall panels shall be installed at bottom of pit at base of
recess level, on top of polyethylene sheeting. Allow 2 minimum
airspace between walk-in wall and building wall. Floor
insulation shall be layers of 2 inch to provide 6 inches for
freezer (minimum R-28) and minimum 4 inches for cooler of ridged, extruded polystyrene insulation with a minimum
compressive strength of 40.0 lb/ sq. inch. Joints shall be
staggered. Vapor Permeable Separation of 15 pound felt,
protective slip sheet shall be applied over insulation, flashed
up height of base, with joints lapped 6 inches minimum. Finished
floor wearing surfaces shall be supplied and installed by other
then Kool Star.
F. Insulated concrete slab
red wood breaker: Where walk-in wall panels are to
be installed at finished floor level, redwood thermal breaker
shall be utilized to frame subfloor pit area.
Minimum 3 space
between outside edge of breaker and finished building wall shall
be maintained to allow for required 2 final air space. FSEC
shall provide a sub floor membrane of Asphalt emulsion (ASTM
D1187 clay type) applied to clean, smooth concrete sub-floor.
Coordinate depth of depression with General Contractor. Cover
with 6-mil polyethylene sheeting extending under redwood thermal
breaker, 20 wide rolls shall be utilized to minimize seams,
when seams are required; joints shall be lapped 6 inches
minimum. Sub-floor membrane shall continue up to the top of the
depression past finished floor level. Floor insulation shall be
layers of 2 inch to provide 6 inches for freezer (minimum R-28) and
inches for cooler of ridged, extruded
polystyrene insulation with a minimum compressive strength of
40.0 lb/ sq. inch. Joints shall be staggered. Vapor Permeable
Separation of 15 pound felt, protective slip sheet shall be
applied over insulation, flashed up height of base, with joints
lapped 6 inches minimum. Walk-in wall panels to be installed at
finished floor level. Finished floor wearing surfaces shall be
supplied and installed by others.
- Doors and Hardware:
The standard swing door clear
opening size shall be 34" wide by 78" high and hinged per the
FSEC supplied drawings. Doors shall be flush; infitting style
constructed of fiberglass reinforced plastic door perimeters and
jamb. Metal, wood, vinyl and PVC frames are not acceptable.
Doors and door frame shall have 1½ steps. Doors shall be
insulated with a full four inches (4) thick core of same
insulation materials specified for the wall panels. Each door
shall be provided with a three-sided snap-in magnetic gasket and
sweep gasket to seal the bottom of the door. Doors shall be
mounted with two Kason #1256 cam lift hinges, one Kason #1229C
or keyed door latch with interior safety release, #1094 or equal
door closer, one 2" solar power digital thermometer and one pre
wired pilot light and switch to interior mounted 100 watt vapor
proof light fixture with protective globe. Freezer door jamb
shall be provided with one four sided heater cable with a
stainless steel threshold and one heated air vent to equalize
pressure between the interior compartment and exterior spaces.
- Available Optional Accessories:
- Hermetically sealed 18" x 18" triple paned view port
windows. (heated for freezers)
- Interior and exterior kick plates in stainless steel or
aluminum diamond plate finish.
- Third hinge
- Rack and pinion attached arm type door closer
- Flush mounted stainless steel cased temperature alarm
with digital LED display and audio and visual alarms with 30
minute delay and silencer button, remote notification,
optional panic alarm, door ajar alarm and multi-point
interior ramp for prefabricated floor, advise
walk-in designer if ramp is to meet
tile at walk-in exterior
Exterior ramp for prefabricated floor
- Entrance door strip curtains.
- Double acting traffic doors.
- Sliding & custom swing doors.
- 4" Surface mounted dial thermometer.
- Fire axe with stainless steel mounting bracket.
- Flush mounted 3-way switch and pilot light.
- Bumper rail.
- Stainless steel or aluminum diamond plate corner guards
- Ceiling enclosures to match walk-in wall panel finish to
24" in height.
- Escutcheon plates.
- Fluorescent light fixtures with low temperature ballast
for freezer applications.
- Locking bar.
- Outdoor membrane roof cap.
Suspended ceiling hangers / structural support for
oversized walk-in compartments.
- 30" wide by 30", 40" or 60" solid reach-in doors.
- Glass reach-in doors provided with lights and shelving.
- Klear Sight Door:
Klear Sight Door opening size shall
be 36 wide by 84 high. Viewing area of door shall be 24 x 48
and shall be full door thickness; minimum 3 panes tempered
safety glass. Freezer doors shall have heated glass. Doors shall
be flush; infitting style constructed of fiberglass reinforced
plastic door perimeters and jamb. Metal, vinyl and PVC frames
are not acceptable. Doors and door frame shall have 1 ½ steps,
providing an airtight flush fit. Doors shall be insulated with a
full four inches (4) thick core of same insulation materials
specified for the wall panels. Doors shall be finished with
stainless steel interior and exterior. Each door shall be
provided with a three-sided snap-in magnetic gasket and sweep
gasket to seal the bottom of the door. Doors shall be mounted
with two 7 strap cam lift hinges and one 5 strap cam lift
hinge, one door pull, one pinion shaft door closer in compliance
with the Grade 1 requirements of ANSI standard A156.4. 6 high
impact bumper, protruding 7/8 off face of door shall be mounted
between bottom hinge and viewing area. Freezer door jamb shall
be provided with four sided heater cable with a stainless steel
threshold and one heated air vent to equalize pressure between
the interior compartment and exterior spaces.
BENEFITS of the Klear Sight Door
Visibility in your walk-in Cooler AND Freezer:
Encourages cleanliness and organization
Consistent viewing by management and inspectors
Allows kitchen staff to view product and inventory before entry
Enhances safety allowing view of incapacitated or injured persons
Enhances security from theft, sabotage and employee non-production and unauthorized activities
- Quality Assured:
Each KOOL STAR UNIFOAM prefabricated panel uses only the
highest quality of materials and U.L. Listed and recognized
Each panel is subjected to a five point quality check system to
delivery a product of the highest standards.
- Installation Instructions:
A complete set of shop drawings, parts lists, packing slips
and set of instructions covering the assembly of the walk-in
panels and accessories shall be supplied.
- Refrigeration System Specifications:
The refrigeration system shall be
U.L. Listed and of standard manufacturer as supplied by KOOL
STAR. The system shall be contained within a galvanized steel
housing for all weather protection with a control panel for all
A. Remote Condensing Unit:
The system shall be equipped with a factory new hermetic or
semi-hermetic compressor motor as manufactured by Copeland or
equal. Each unit shall be supplied with a crankcase heater,
liquid line with filter drier and sight glass, suction line with
filter, receiver with fusible plug and shutoff valve, compressor
start kit for single phase units, contactor for three phase
units, time clock (for freezers only) and high/low pressure
control. Each condensing unit shall employ refrigerant R-22 and
R-404A for medium and low temperature application respectively.
All condensing unit selections are based on capacities
engineered to operate in 100 degree Fahrenheit ambient
conditions. All condensing units are shipped with a holding
charge of dry nitrogen.
B. Evaporator Coil:
The condensing unit is capacity matched to a NSF, U.L. Listed
evaporator coil constructed of a rust-free aluminum housing
consisting of staggered copper tubes expanded into corrugated
aluminum fins for increased heat transfer. Medium temperature
applications employ "off-cycle" defrost using 115 volt fan
motors. Low temperature applications employ electric defrost
method using 230 volt fan motors and heating element.
Evaporators are supplied with mounted TX valve and solenoid
valve. Thermostat is shipped loose.
C. Self Contained
PRS-2 Refrigeration system is
available in ceiling mount as well as wall mount indoor and
outdoor models. The PRS-2 Refrigeration System is a convenient
combination of condensing unit and evaporator coil in one
package. Each refrigeration system is fully assembled,
evacuated, charged, run tested and wired at the factory for
reliable performance. Adding to that assurance is a warranty
covering parts, labor and the compressor for one year. An
optional extended four year compressor warranty is available.
PRS-2 Refrigeration System provides for a simple installation.
Refrigeration labor costs are greatly reduced because there is
no cooper piping, refrigerant, piping or other components to be
field installed. Certain indoor models come with a power cord so
the unit can be plugged in. Indoor units also have a standard
condensate evaporator pan to eliminate the need for a drain
PRS-2 Refrigeration System has a coated evaporator coil as a
standard. Optional remote condensing unit with line set up to
Refrigeration Installation Instructions