Insulation success at warehouse

EPS insulation success at warehouse

Isoprojects, a member or the Isowall SA group of companies, has been working on a mammoth food service distribution centre in Kosmosdal, Midrand. This cavernous facility is located along the N1 highway, and has halls and chambers akin to the pyramid of Giza. Unlike the pyramids, however, this is a state-of-the-art warehouse belonging to Digistics, a company specialising in multi-temperature distribution centres for the food sector. The warehouse will serve KFC outlets in the area and comprises office space, packing space, a chiller, freezers and airlocks.

An abundance of EPS

In just a matter of months, kilometers of expanded polystyrene (EPS) panels, many an impressive 200 mm thick, have been embedded under the floors, erected as walls, hung as ceilings and clad to internal pillars to both erect and insulate the specialised, temperature controlled sections of the centre. EPS is also being used to envelop three freezers, one chiller and an airlock facility, as well as an air-handling unit with ducting. Continuous EPS in the walls, floor and roof will ensure the integrity of the insulation envelope for the main freezer room whose volumes total 30 m by 30 m and nine metres high.

Isoprojects’ involvement

Work started on the Kosmosdal site in March 2009. “The uneven and wet terrain we had to work on in the beginning and working around other trades on site were the two major challenges on this project. We are, however, on track and nearing completion,” says Isoprojects Director Haupt Beneke.
He adds his company has built two such distribution centres for Digistics already, and has done further repair work on a third site. “The company looks forward to building on this relationship with Digistics in future, as the food service sector continues to expand,” he says.

Efficiency of a different kind

This project was different to others in that it features two freezers leading into another freezer before going to the air lock. The freezer doors, also manufactured by Isowall/Isoprojects, are highly specialised and feature a polyurethane core.. Each door has been capped with blue fibreglass to form a thermal break.Even the door lever is unusual, and incorporates a special heater tape that seals against the gasket of the frame to stop ice from forming. The door seals at the bottom against a heated sill that is cast into the floor to form a thermal break between the inner and outer concrete.

The smooth finish of the insulation panels – which comprise sheets of EPS laminated to pre-painted galvanized steel skins – look neat and provide a hygienic surface, especially important in the food service industry.

Digistics warehouse
• Complete by Isoprojects
• Used kilometers of EPS
• EPS panels up to 200mm thick specified
• EPS used for floors, walls, ceilings, cladding
• EPS used to envelop the freezers
• EPS used for insulative panels

Layout:
HIGHLIGHT: it features two freezers leading into another freezer before going to the air lock. Even the door lever is unusual, and incorporates a special heater tape that seals against the gasket of the frame to stop ice from forming.

eps_insulation1
Laminated EPS panels at the Digistics distribution centre are easy to clean.

eps_insulation2
Pictured above are the freezers and chiller as seen from the main warehouse hall, and EPS panels in the foreground awaiting installation.

eps_insulation3
The Digistics distribution centre is pictured above from outside the facility. Each entrance is a docking bay for trucks.

eps_insulation4

The gap in the ceiling behind the workers gives an idea of the height of the freezers at the Digistics distribution centre. Beyond the expanded polystyrene panels is the main roof of the warehouse in which the freezer is housed.

eps_insulation5

Pictured above is the largest of the freezers with Isoprojects workers cutting the nine metre long, 200mm thick EPS panels.

eps_insulation6

The roof panels are clearly visible in this image. Even the internal weight-bearing columns are also neatly wrapped in a snug EPS suit to ensure complete insulation.