The panel thickness sets the power bill.
A thin panel doesn't fail all at once. The compressor just runs longer, every hot day, for the life of the room. Too thick and you paid for material you didn't need. We calculate the temperature delta, choose the panel and the skin, install every joint tight, and service the room afterward. Built by operators who paid those utility bills themselves.
Pick the thickness from the temperature
| Panel thickness | U-value (W/m²·K) | Holds down to | Typical use |
|---|---|---|---|
| 75mm | 0.30 | -5°C | Light cooler, ambient-adjacent |
| 100mm | 0.23 | -15°C | Cooler, produce, dairy (35–40°F) |
| 150mm | 0.15 | -25°C | Freezer (0°F), frozen storage |
| 180mm | 0.125 | -35°C | Low-temp freezer |
| 200mm | 0.113 | -50°C | Blast / ultra-low temp |
The core is high-density 42 kg/m³ PIR/PU, FM-approved, with a B-grade fire rating. "Holds down to" assumes a 25°C ambient. Put the same room inside a hot, unconditioned warehouse and the build may need to go one step thicker.
What changes the specification
- 01Camlock PU or continuous PIRCamlock PU panels use zinc-coated locks, install quickly, and carry a B2 fire grade. Continuous PIR panels carry B1 and suit longer runs, larger rooms, and stricter fire requirements. We choose from the build and the code.
- 02Skin matched by wallStainless 304 belongs on walls that get hosed or touch product. Galvanized or painted color-plate steel works on dry walls. We specify the skin by surface, so you're not buying stainless where it adds nothing.
- 03Insulation that stays dry10-year panel warranty, 20-year service life. Closed-cell porosity and low water absorption keep the R-value where it started. That only pays off when the joints and vapor control are installed right.
- 04Openings belong to the envelopeEvery door, floor joint, curb, and penetration interrupts the insulated shell. We detail those connections with the panel system instead of leaving separate trades to meet in the field and hoping the vapor seal survives. Door types →
The joint matters as much as the panel.
Panels on a truck are only material. A crooked start, an open camlock, a missed sealant joint, or a broken vapor line puts moisture into the foam and load onto the refrigeration.
We install what we supply and service it for life. Square corners, sealed joints, vapor control, floor transitions, and door openings stay under one crew. If a joint opens or a skin gets hit, the people who built the room know how it went together.
Questions we answer every week
Should I use PIR or PU panels for cold storage?
Both use a high-density 42 kg/m³ foam core, but they differ in fire performance and installation. Camlock PU panels connect mechanically, go up quickly, and carry a B2 fire grade. They fit most walk-ins. Continuous PIR panels carry B1 and make more sense on long wall runs, larger rooms, or where the fire code is stricter. Neither is automatically the better panel. The building, room size, code, and connection details decide it.
How thick should cold-storage panels be?
Start with the difference between the room temperature and the ambient around it. The working rule is 100mm for a cooler, 150mm for a 0°F freezer, and 180–200mm for low-temperature or blast rooms. A hot, unconditioned warehouse may push the choice one step thicker. More panel costs more up front, so we don't add thickness automatically. We weigh that cost against the refrigeration load over the room's working life.
What panel finish do I need for a washdown room?
Stainless 304 on walls that get hosed or can touch product. Galvanized or painted color-plate steel is usually enough for dry storage walls. The joints and corners matter as much as the skin: once wash water gets behind the metal, it reaches the foam and stays there. We specify the finish wall by wall and detail sealed joints and coved corners, rather than charging stainless prices for the whole room.
Can insulated panels go inside an existing warehouse?
Yes. That's a box-in-a-box conversion, and it fits a lot of Northeast projects where land and ceiling height are tight. Panels go inside the existing shell; a freezer also needs an insulated floor build. Before we call it workable, we check clear height, roof and structure, slab condition, drains, door traffic, and condenser location. The existing building can save real construction, but only if the cold room fits without creating a bad product path or an impossible service area. Run the conversion estimator →
Start with the temperature and the space.
Choose Cold storage room in the estimator for panel area and refrigeration load. Or send the room dimensions, target temperature, ambient, and washdown requirements, and we'll tell you what envelope is realistic.
Or call (201) 256-1231 · We respond within 1 business day.