Freezer Floor & Cold Room Applications

ENGINEERED FLOORS

For Freezer and Cold Room Facilities

Freezer Floors – Ground Heave Solutions

Frost heave is a term commonly used to describe the displacement of structures caused by ice depositing underneath all or portions of structures operating constantly at low temperatures. Most refrigerated facilities are constructed with a slab-on-grade. In cases where the slab persistently operates below freezing (0°C/32°F), frost from moisture in the soil will form underneath the slab unless some form heat below the slab is provided. If the sub-slab is not heated, frost heave will not only eventually destroy the slab but also create other significant structural problems within the facility.

A properly designed CUPOLEX® passive or mechanically heated aerated concrete floor will provide sufficient heat to prevent frost formation under the slab; thereby preventing structural failures while minimizing the parasitic heat gain to the refrigerated space.

DESIGN FEATURES

The mechanical or passive air distribution below CUPOLEX® floors is engineered to guarantee an unrestricted air flow below the entire concrete slab.
In warmer climate areas, the engineered CUPOLEX® floor can be easily vented as a passive or active system using outside air
Significantly reduces moisture that may condense inside the CUPOLEX® void space
Maximum amount of heat entering the subsoil
Under-floor heat can be supplied from outside air, warm exhaust air from a process equipment, or any other conveniently located space.
Provides additional protection and better temperature control with heated air
Allows ventilating from a furnace/makeup air unit or recover heat from the hot gas coming off the refrigeration system.
Can be designed as a “closed” systems, meaning the air used in the under-floor system is recirculated after adding heat and dehumidifying.
Allows the use of a fan to aerate the sub-floor network
Can use heat reclaimed from refrigeration system

BENEFITS & ADVANTAGES

Easy to inspect
Simple design and lower cost than other electric, hydronic heating systems or vented piping systems
Minimises maintenance
No risk of plugging of conventional pipe branches by frost, ice, or other debris.
Energy cost is less than electrical resistance
No environmental concerns of leaking glycol into the soil
Manufactured to ISO 9001:2015 high quality standards

APPLICATIONS

Refrigerated freezers (distribution and long-term storage)
Blast freezers (spiral freezers, blast cells, hardeners, etc.)
Ice rinks
Curling sheets

Engineered Isol-Cupolex® System

Cupolex offers unique and cutting edge engineered floor systems options for freezer and cold facilities, such as the pateneted Isol-Cupolex® system.

The engineered Isol-Cupolex® insulated crawl space is designed to create an insulated passive or active vented subfloor as a monolithic concrete pour, which significantly saves time and construction cost, compared to a two-pour insulated concrete floor slab. The form-based concrete geometry created by the engineered Isol-Cupolex® does not weigh on the insulation but the loads are transferred directly to the supporting subbase.

Customized Design Package

Design Application Analysis – Our firm helps clients determine the Engineered CUPOLEX® system solutions that address specific site needs.

Value Engineering – CUPOLEX® works with value-engineering at the forefront of each project. We provide the best alternatives for every project.

Structural Systems Evaluation – Every project is unique. Our team reviews multiple structural CUPOLEX® systems to determine the best fit for each project.

Preliminary Structural Design – We work with our clients and their designers to determine the performance of a given CUPOLEX® structure under the prescribed loads and/or other effects or requirements while using principles of statics, dynamics and mechanics of materials to determine the size and arrangement of CUPOLEX® structural elements.

Material & Cost Estimating – Our collective experience helps us to provide our clients with material recommendations to reduce costs while maintaining the function of the CUPOLEX® structure.

Engineered Design Drawings – Issued for construction (IFC) and supported with FEA structural calculations, PE stamp, construction documents and specifications.

CUPOLEX® Installation Shop Drawings – With detailed CUPOLEX® formwork installation procedures issued to contractors.

Onsite Support – Construction training, monitoring and inspections for successful construction, and we present the information in a comprehensive report.

Construction Administration – We provide responses to request for information and interpretation of CUPOLEX® design drawings, with completion statements and regulatory compliance reporting where required.