STANDARD SPECIFICATIONS FOR COOLERS & FREEZERS

FEATURES OF KOOL STAR'S HD SPEC LINE COOLERS & FREEZERS:

• 4", 5” or 5 ½” Thick KOOL STAR prefabricated modular panel construction.
• 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 light fixture.
• Solar digital thermometer.
• Wall closures and cove base included.
• Heated air vent and 4 sided door heater cable. (freezer only)

Cooler and Freezer Specifications

1. General:

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 relocation provisions.

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 responsibility.

2. 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 ¾ 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 4’0” 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 specified requirements.

3. Insulation:

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 degrees Fahrenheit.

4. 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 steel.
• 24 Ga. smooth baked white enamel on galvanized steel. (USDA)
• .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)

5. Floor Construction: (select one):

A. 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. Typical 2” 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.

B. Prefabricated floor: 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.

D. Where recessed pre-fabricated insulated floor is provided in 4” recess, wall panels shall be coupled by steel cam action locks, foamed in place, maximum 4’0” 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 this transition.

Prefabricated floor installed in recess: Prefabricated floor panels shall be constructed the same as the prefabricated floor on finished floor. When concrete, 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 depression, 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 depression, 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 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. Walk-in wall panels to be installed at finished floor level. Finished floor wearing surfaces shall be supplied and installed by others.

6. 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.

7. 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 scanning.
• Built-in 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 and wainscot.
• 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.

8. 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

9. Quality Assured:

Each KOOL STAR UNIFOAM prefabricated panel uses only the highest quality of materials and U.L. Listed and recognized component parts.

Each panel is subjected to a five point quality check system to delivery a product of the highest standards.

10. 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.

11. 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 electrical components.

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 Refrigeration System

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 line.

PRS-2 Refrigeration System has a coated evaporator coil as a standard. Optional remote condensing unit with line set up to 50’ available.

12. Refrigeration Installation Instructions