TECHNICAL SERVICES HANDBOOK September 2019 - KPS Global® · 2019. 9. 25. · 4 ©KPS Global 2019...

TECHNICAL SERVICES

HANDBOOK

September 2019

©KPS Global 2019 2

©KPS Global 2019 3

Contents Walk-In Suppliers to Walmart……….……………………………………………………..4 KPS Global…………………………………………………..…………………………………………….4

KPS Global Walk-Ins………………………………………..…………………..……….…….5 Customer Service………………………………………..…………………………………………….5

How Can KPS Global Help You?......…………………………………..……….………..6 Information for Non-Budgeted Quotes ………………………………………………………6

Walk-Ins Information………………………………………………………………….………7

Walmart Slide Door and Roll Up Door Information…………………….….…….8 Chase Doors……………………………………………………………………………………………..9

Jamison Door Company……………………………………………………………………….....10

Frank Door………………………………………………………………………………………………11

Regent Door……………………………………………………………………………………………12

Hired Hand/Roll Seal………………………………………………………………………………13

Walmart Walk-In Glass Reach-In Door Providers……………………….……….14 Anthony International………………………………………………………………………………14

Thermoseal Industries.….…………………………………………………………………………15

Commercial Refrigerator Door Company………………………………………………….16

Merchandiser Shelving………………….…………………………………………………………17

Chase Double-Acting Traffic Door…….………………………………………………………18

Strip Curtains…………….………………….…………………………………………………………19

Walmart Walk-In Service, Sustainability and Maintenance…………….…..20 Walk-In Panel Opportunities…………………………………………………………………….20

A Look Into A New Supercenter Under Construction………………………………….43

Walmart Walk-In Hinged Door Hardware Nomenclature………………………......45

Common Terminology for Walk-Ins at Walmart………………………………………..48

Basic Installation Notes……………………………………………………………………………51

Basic Maintenance Notes…………………………………………………………………………52

Preventative Maintenance Notes………………………………………………………………53

Condensation………………………………………………………………………………….…54 Condensation and Ice Causes Prevention…………………………………………………54

Installation and Maintenance Checklist……………………………………………………56

Condensation Basics………………………………………………………………………………..57

Condensation Graphs……………………………………………………………………………….58

FUSIONFRAME.……………………………………………………………………………….…64

©KPS Global 2019 4

Walk-In Suppliers

KPS Global Walk-Ins

4201 North Beach St

Fort Worth, TX, 76137

800.633.3426

kpsglobal.com

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©KPS Global 2019 5

Sales and Installation/Service Department

Chad Carrol Outside Sales Manager

817.528.5032 [email protected]

Jimmy Seals Inside Sales Manager


Tom Beatty Vice President of Construction

[email protected]

Junior Burnside Sr. Director of Construction Services

[email protected]

Jason Bratcher Director of Construction Services


Chris Stewart Installation Manager


Mike Odle Service Manger


Kevin Stone Turnkey Manger


Barry Walsh Project Manager


Don Davis Project Manager


Barry Beard Project Manager


Randy Wolf Project Manager


Jeremy Boatner Project Manager (Sam’s Club)


mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

©KPS Global 2019 6

How Can KPS Global Help You?

KPS Global provides walk-in cooler and freezer panels for:

1. New stores 2. Remodel projects 3. Cap-ex projects 4. Non-budgeted emergency projects 5. Health department repairs or replacements 6. Associate safety repairs or replacement 7. Upgrading to current specification 8. Compliance upgrades 9. Damaged and inoperable product 10. Insurance claims and replacements/repairs

Information for Non-Budgeted Quotes

Non-budgeted emergency project information needed for a quote:

a) Store number and address b) Contact person for quote and operation c) Immediate emergency or timeframe available d) Description of work required e) Photos if available f) Do you need to meet there for a pre-bid scope of the project? g) If door replacement is needed, what brand…Jamison, Regent, Chase? h) Is new shelving required? i) Any general information needed about location, manager, or other issues

©KPS Global 2019 7

Walk-Ins Information The following pages contain information about Walk-In suppliers as well as troubleshooting for

commonly encountered issues.

Walk-In

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©KPS Global 2019 8

Walmart Slide Door and Roll up Door

Information

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©KPS Global 2019 9

Chase Doors

What am I seeing? Chase Manual / Powered Slider Doors for Walmart

What does it mean? Chase Door is a principal supplier to Walmart in various formats. They are

approved as a new or replacement product on all Walmart Walk-Ins.

Chase “ColdGuard”

www.chasedoors.com

(800) 543-4455

Chase Doors

10021 Commerce Park Drive

Cincinnati, OH 45246

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http://www.chasedoors.com/

©KPS Global 2019 10

Jamison Door Company What am I seeing? Jamison Retail Pro Model Standard New Supercenter Slide Door for Walmart

What does it mean? Jamison is a supplier to Walmart in supercenter formats. They are approved

as a new or replacement product on Walmart Walk-Ins. Jamison offers a Mark IV model door for

premium pricing but offers more features. Also, Jamison created a Cap-Ex Specification door

installed in Sam’s.

Jamison Door Company

PO Box 70

Hagerstown, Maryland 27141-0070

1-800-532-3667

301-733-3100

www.jamisondoor.com

[email protected]

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http://www.jamisondoor.com/mailto:[email protected]


Frank Door

What am I seeing? Frank Manual Slider Doors for Walmart/Sam’s Club

What does it mean? Frank is a supplier to Walmart on replacement door orders. They are approved

as replacement product on Walmart Walk-Ins.

Frank Door Company

413 Howard Boulevard

Newport, North Carolina 28570

Phone: 888-833-3667

https://frankdoor.com/Slide-Single-Door

Email: [email protected]

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https://frankdoor.com/Slide-Single-Doormailto:[email protected]


Regent Door

What am I seeing? Regent Manual / Powered Slider Doors for Walmart/Sam’s Club

What does it mean? Regent Door is principal supplier to Walmart in various formats. Regent is the

preferred product for Cap-Ex replacement projects. They are approved as new or replacement

product on Walmart Walk-Ins.

Regent Door

8055 Production Avenue

Florence, KY 41042-3094

800-826-3100

http:/www.aicinsulate.com/regentsingle.htm

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Hired Hand/Roll Seal

What am I seeing? HH Technologies Roll Seal RS-500 N/E Plus Sam’s Club/Supercenter Door

What does it mean? Hired Hand/Roll Seal is a principal supplier to Walmart in Supercenter/Sam’s

formats. They are approved as a new or replacement product on all Walmart/Sam’s Walk-In’s at

time of this publication. Current door offering is the RS-500 WIC Door Plus TSI (Track Switch

Integration).

Technical Service Line:

800-668-2815

• Live help is available Monday-Friday 7:30 to 5:00 CST

• Automated technical assistance with self-repair instructions for common issues is available after hours, weekends, and holidays

• Emergency Technical Assistance is available after-hours, weekends, and holidays. The caller must go through the automated prompts to be transferred to a Technical Service

Advisor.

Technical Service Team

Shane Young ext. 1230

Chet Graves ext. 1312

Main Office

256-287-7000

Contacts:

Kerry Hancock ext. 1121

Randy Remington ext. 1122

Cell: 256-339-0645

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Walmart Walk-In Glass Reach-In Door

Providers

Anthony International

What am I seeing? Anthony Glass Reach-In Doors Sam’s Club/Supercenter Door

TorqueMaster™-for complete door adjustment in seconds, Anthony’s Torquemaster quickly adjusts

door closing tension, sag and centers the door in its frame with only a regular screwdriver.

Anthony International

12391 Montero Avenue

Sylmar, CA 91342

Toll-Free: 800-772-0900

Fax: 818-361-9611

http:/www.anthonyintl.com/en/ContactUs.aspx

http:/www.anthonyintl.com/en/Products/DoorsFrames/101Series.aspx

What does it mean?

Anthony Door is principal

glass door provider to

Walmart. They are

approved as a new or

replacement product on

Walmart/Sam’s Walk-Ins

at time of this

publication.

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THERMOSEAL Glass Reach-In Doors

What am I seeing? THERMOSEAL Glass Reach-In Doors

What does it mean? THERMOSEAL is a replacement door/frame/parts supplier to Walmart. They

are approved as a replacement product on all Walmart/Sam’s Walk-In’s at time of this publication.

Thermoseal Industries, LLC

600 Jersey Avenue

Gloucester City, NJ

Tel: 800-456-7788

Fax: 856-456-0989

Email: [email protected] www.thermoseal.com

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mailto:[email protected]://www.thermoseal.com/


Commercial Refrigerator Door Company

What am I seeing? Commercial STYLELINE Glass Reach-In Doors Sam’s Club/Supercenter Door

What does it mean? STYLELINE is a supplier to Walmart in Supercenter/Sam’s Formats. They are

approved as a new or replacement product on all Walmart/Sam’s Walk-In’s at time of this

publication

Commercial Refrigerator Door Company

6200 Porter Road

Sarasota, FL 34240

Tel: 800-237-3940 / 941-371-8110

Fax: 941-377-2850


www.styleline.com

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mailto:[email protected]://www.styleline.com/


Merchandiser Shelving

What am I seeing? Merchandiser Shelving

Anthony or STYLELINE glass reach-in doors have shelving behind them by different suppliers. These

suppliers are based on specified location or prototypes at Sam’s or Walmart Supercenters.

What does it mean? The suppliers of walk-in panels also supply the glass door shelving for Walmart

Walk-Ins at time of this publication.

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Walmart Double-Action Doors

The Chase Retailer R25 Insulated Impact Traffic Door is your solution to meeting the requirements

of the 2007 Energy Independence and Security Act (EISA). The R25 utilizes time proven rotational

molding technology and urethane foamed-in-place insulation to meet the insulation requirements

set forth in the EISA Energy Bill.

What am I seeing? Walmart requires Double Action Doors for Walk-In Service Doors in prep areas

principally. EISA 2007 also requires the door to match the R-Value of the wall of the Walk-In. Door

displayed here is the Chase R-25 product used by Walmart today.

What does it mean? The Walmart Walk-In providers supply all the Double Action doors that attach

to walk-in panels. These are compartment to compartment or to the Stock Room or Sales Area.

What could I do? If a door is damaged and needs replacement, most Sam’s Club and Walmart

Stores employ the Double Action Doors to effectively service their customers. Parts replacements

are available-visit www.chasedoor.com for details.

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Walmart Strip Curtains

What am I seeing?

Walmart requires strip curtains on Walk-In Service Doors.

EISA 2007 also requires an added curtain on doors to assist

with energy consumption. Examples below are Chase and

Kason—two main suppliers to Walmart Walk-In providers.

What does it mean?

The edge strips should be a warning orange or red color as

the photo indicates. A curtain will be subjected to damage

if not properly installed and proper temperature rated

curtains used for coolers or freezers.

Many Sam’s Clubs or Walmart stores are keeping a stock of

curtains on hand for maintenance purposes.

Chase Products – www.chasedoors.com

Kason Industries – www.kasonind.com

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http://www.chasedoors.com/http://www.kasonind.com/


Walmart Walk in Service,

Sustainability and Maintenance

Walk-In Panel Opportunities

The following pages contain information about potential problems and solutions

regarding Walk-In installation and maintenance.

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What am I seeing? Outside corner of a grocery freezer where Venture Tape is applied, and the

corner is pulling apart. The beaded metal finish (seen in picture) is a finish from the 1990’s-early

2000’s. The metal is an embossed 26 GA galvanized.

What does it

mean? The corner

is experiencing

movement due to

two possible

things-impact

damage from

pallet loading or

possible

movement at the

base of the wall.

Ice may be

growing in the

seams.

What could I do?

Exterior-cut away

gasket and fill

seam with

silicone to match

finish. Add lag

bolts of proper

length from

exterior through

to adjoining wall

panel. Add

batten strip on

interior and/or

exterior of corner.

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What am I seeing? Photo of Ice Cream Freezer starting to pebble due to defrost duration, rising box

temperature and/or drain line performance. The evaporator strains the moisture from the

refrigerated envelope air mass. Getting the moisture out of the freezer is critical for the

functionality of all the parts that make up a walk-in freezer. Steam from defrost can create

“pebbling”.

What does it mean? The evaporator defrost can introduce moisture into the storage freezer through

steaming and slow or stopped drains. The frost and pebbling will grow on ceilings/walls. This

becomes a safety issue for associates.

What could I do? Shorten the defrost cycle incrementally to eliminate the pebbling. Verify that the

drain is clean and that the drain heater is functioning. Keep back stock away from the evaporator

cabinet to help with proper air flow.

Cover plate here is missing from electrical junction box. Drain heater may be absent or shortened. D

Pebbling in front of coil

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The low temperature of the boxes coupled with varying pressures because of door opening/closing

creates a draw for warm, moist air to leak through improperly seal joints and panel intersections.

What am I seeing? Small Ice Cream Freezer starting to indicate leak at wall to top intersection.

What does it mean? Ice is formed by moisture infiltrating into the freezer. Notice the origin point, or

point closest to the wall, is clear ice, not frost. Clear ice indicates a joint leak.

What could I do? Defrost the box and verify tops are properly lagged down. Verify that no debris

was under top to wall intersection preventing a solid seal. Add butyl to the seam-interior and cover

with a batten strip. Exterior-remove top trim silicone top to wall intersection and reinstall top trim.

Note product stacked all the way to ceiling, limiting airflow.

Note the origin point (closest to the wall) is clear ice, not frost. This indicates a joint leak.

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What am I seeing? Grocery freezer starting to frost up on ceiling seams, shortly after repairs to the

freezer door section.

The evaporator refrigeration cycle strains the moisture from the refrigerated envelope air mas,

when the evaporator is placed above a service door; this is not the best location and should be

avoided if possible. The product stacked tight to the ceiling obstructs airflow and creates areas

where frost can build up.

What does it mean? The evaporator is located above a hinged door (recently replaced). The door

open time adds moist air taken up and out of the evap discharge. The frost will grow on ceilings

and walls. This becomes a safety issue for associates.

What could I do? Relocate evap to a side or end wall if possible. Encourage store to keep product

stocking down from evaporator air flow. Verify strip curtain is intact and door is closing properly

and completely.

Frost developing on the warmest spot in the walk-in (#1)

Door section with recent repairs (#2)

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What am I seeing? This grocery freezer was starting to frost up on seams. Battens were applied to

the freezer walls (see #1)

Battens are a temporary fix for seams that display some movement or icing. This procedure adds

usable service life to the affected walk-in, but proper installation is vital. This project was not

properly sealed at edges of the batten material after battens were applied.

What does it mean? The battens were sealed on the panel seam under trim material; however, it is

vital that the batten strip edges are sealed with silicone. This sealing of the edge isolates the area

around seams for a tighter seal (see #2).

What could I do? Warm up the box and apply similar color silicone to the batten strip edges (see

#3). The batten strip Fasteners at 12” centers are properly fastened in this photo (see #4).

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What am I seeing? This grocery freezer is starting to frost up on seams. Battens were applied to the

freezer walls.

Battens are a temporary fix for seams that display some movement or icing, and proper installation

is vital. This one year old installation project was properly sealed after battens were applied. Note

the walls are still clear of ice and battens look tight to surfaces. The edges of the batten material

create a better seal when a silicone barrier is added at edges.

What does it mean? The battens were sealed on the panel seal under trim material; however, it is

vital that the batten edges are sealed with silicone. This install shows silicone applied to batten

edges (see #1)

What could I do? Battens are a temporary repair to a more serious problem. Monitor the walk-in

closely at each PM cycle. Fasteners at 1” centers are properly installed in this view.

This photo illustrates an

example of correct sealing of

edges (See #1).

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What am I seeing?

Liner panel installation details:

Remove any butyl tape, sealants or metal covers off interior panel joints

Remove gaskets from the joints to allow for butyl sealant to be

installed in panel seams prior to liner installation

Cut thermal break at bottom of walls where liners are being

installed about 1 ½ inch up A.F.F

Apply butyl to open joint and at base of panel to the floor on

interior of box and cover with Venture tape to protect and add

extra seal

Installation of liner panels to walk in cooler and freezer

Liners are attached to wall with screw placed 23” OC in joint

Butyl applied as per print details in all seams at floors, corners,

and walls

Spray foam gaps at top and corners

Install closure trim supplied with panels

Silicon all exposed edges of trim

Install battens on front wall of Freezer only around door section

as required if total sealing is required

Install butyl sealant, venture tape and insulated battens on top

seams if requested

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What am I seeing? Liner panel installation procedure.

1. Shut down cooler or freezer after unloading product to a refrigerated trailer or separate walk-in storage associated with the project for a minimum of 48hrs.

NOTE: To effectively seal panels, the repair needs to be performed within a defrosted unit

2. Install liner panels on walls, with details following supplied drawings from KPS Global.

3. If Liners are required in the cooler (the cooler can remain running if evaps can be

isolated from repair wall with a curtain).

Process – install an air curtain along the wall

against the freezer far enough out for workers-

approximately 4 feet

4. After all ice is removed from seams, install repair with liner panels can begin.

5. When complete, the freezer will have liners on common or all interior walls, the wall against

the freezer in adjoining cooler can be lined as

well for extra protection, top and floor trim

installed around door section, tops and floor

6. Repair package includes all necessary trim, fasteners, silicone, and butyl. In addition,

detailed drawings showing fastening method

are included.

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What am I seeing? A freezer starting to frost up on seams. Liner panels were applied to the freezer

walls as a short-term repair for icing and thermal problems.

Liner Panels are a temporary fix for walls/seams that display some movement or icing. Proper

installation is vital. Some Cap-Ex and remodel projects call for liner panels in the freezers and

coolers.

What does it mean? The

existing panels were sealed

on the panel seam under

liner panels with butyl and

venture tape. It is vital the

existing panels are defrosted

prior to installing the liner.

This install shows liners with

silicone applied and some

shelving in place.

What could I do? Liners are a

temporary repair to a more

serious problem. Monitor the

walk-in closely at each PM

cycle.

Shelving right against wall

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What am I seeing? Sam’s Club side walls and mullions damaged.

What does it mean? The shelving may not be anchored as left photo indicates here. The shelving is

too close to walls. The pallets are constantly impacting the wall panels and disrupting the joint

seals. Note: from outside of wall to shelving on a POS unit = (+/-12”) the pallet racking steel

should include a product stop cross-rail to help protect walls.

What could I do? Repairs are possible and replacements are sometimes required. Exterior battens

have been used as well as interior battens after panels have been repaired to add life cycle to the

walk-in. Always caution the operators to be mindful of not impacting the wall panels with loaded

pallets.

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What am I seeing? Bakery Prep Area Freezer replacement with a new style Chase Slide door

(manual) – Drop in Ceiling was removed to replace the walk-in panels. Note: Strip curtain safety

strips (orange color) should be applied at edge of door opening.

What does it mean? The Chase door

is a newer product offering that is

being used in some locations.

Note: strip curtain safety strips

(orange color) should be applied

at edge of door opening.

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What am I seeing? Panels being installed into a location that isn’t quite reading. Notice the large

blue and cloudy sky above the C-purling. Walmart Construction and Mechanical Service monitors

construction sites and does everything possible to prevent such premature installations from

happening.

What does it mean? The potential for

damage to the walk-ins, especially

freezers, is almost guaranteed. Although

it’s true all panel suppliers to Walmart

manufacture and install an outdoor

walk-in, they must be designed and

installed to this specification to be

weather secure.

What could I do? In the unlikely event you

see this at a Walmart Construction site,

stop the assembly/Installation process

until the building is weather secure from

rain and snow. The moisture will affect

unsealed walk-in seams. If not

thoroughly dried out before refrigeration

cycle comes online, panels will have

potentially severe damage.

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What am I seeing? Drains are at times issues in backrooms. Many are located as close to the wall

of a walk-in as possible. Due to the location requirement, many times the drains run under the

wall. This creates a potential mold and leakage situation. Other drains are located in the doorways

of walk-ins.

What does it mean? The potential for

damage to the walk-ins, especially freezers,

is almost guaranteed when the drain goes

unmanaged. The growth of mold is a

potential condition. Prevention of Health

Department requested action is vital for

store operations.

What could I do? In the unlikely event you

see this at a Walmart; report the need for

drain relocation and repair for the next

CapEx or Remodel cycle. If a drain is in a

doorway with sloped floors and moisture

and/or icing issues, rework the area around

the drain and have drain raised to appear as

shown in the second photo.

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What am I seeing? A deli or bakery area has Ceramic Tile Floors in many locations. In some cases,

there is no thermal break in the tile even though the sub slab does have a thermal break.

What does it mean? Any time a walk-in floor or floor covering is traveling between a freezer and

ambient conditions, to prevent icing, slip hazards and damage to the floor itself, a thermal break is

recommended.

What could I do? The tile could be cut in the center of opening and removed. The cavity left behind

should be over the subfloor thermal break. That cavity can be filled with Korlyte, Wood, or Epoxy.

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What am I seeing? A thermal break problem under a freezer wall. In some cases, there is no vapor

barrier installed with thermal break in the sub slab. Even though the sub slab does have a thermal

break.

Notice moisture forming on floor in the photo below, mold on doorframe and oxidation moving up

panel surface. Ice is forming toward door opening and slide door facer.

What does it mean? Careful attention must be paid during the construction process to protect the

thermal integrity of insulated floors. There are repair options that can reduce disruption to the

store if the problem is becoming dangerous for associates.

Note thermal break under layer of water.

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What am I seeing? The photos here show indications of potential issues. When walk-ins are

assembled in stores not secure from water. When thermal breaks are soaked thoroughly or not

properly installed, or when pull down isn’t done at a slow rate to remove moisture.

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What am I seeing? The foam in these panels is collapsing or adhesion has been lost to metal skin.

This occurs for a variety of reasons. Many times, the panel has reached its maximum lifecycle.

What does it mean? Although there is still R-Value and the frame will keep the wall in place,

replacement is the best option or the use of liner panels is the temporary repair leading up to a

remodel.

What could I do? Verify the status of the projects for the store. Replace or temporarily install liner

panels to delay replacement until next remodel cycle.

While the frame will keep the wall in

place, replacement is the best option.

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What am I seeing? A thermal break issue for insulated freezer slab. The

thermal break is the material upon which the panel screen and bottom rest.

The properly installed thermal break is vital for walk-in life cycle.

What does it mean? The freezer

temperate zone must have thermal

separation form the ambient conditions or

other walk-ins. The thermal break should

center up under the freezer wall.

What could I do? Stop the installation of

the freezer panels and contact Walmart

Mechanical and Construction Services.

The floor must be prepared with the

thermal break in proper location.

Typical insulated floor design (cross section)

A properly installed

thermal break is vital for

walk-in life cycle.

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What am I seeing? A thermal break issue for insulated freezer slab. The thermal break is the

material upon which the panel screen and bottom rest. The properly installed thermal break is vital

for walk-in life cycle.

This is a remodel project in a Walmart Store adding a new freezer. The photo shows a typical

insulated floor design with Korlyte thermal material inlaid to receive the screed. As this photo

indicates, the installation of walk-ins is made more difficult when other trades fail to perform as

specified.

What does it mean? As on

previous page, the freezer

temperate zone must have

thermal separation form

ambient conditions or from

another walk-in. The

thermal break should

center up under the freezer

wall. In the case shown in

the photo, some areas of

the thermal break will be

outside of freezer if

installation is allowed to

continue.

What could I do? Stop the

installation of the freezer

panels and contact

Walmart Mechanical and

Construction Services.

Walk-In providers will not

proceed in this case.

Proposed exterior

width of walk-in

extends from

technician’s finger to

far wall.

Note the unwanted bend in the thermal break.

Proper installation technique requires squaring boxes with site conditions.

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What am I seeing? Jamb guard problems in freezer door. Loose jamb guards are dangerous for

associates and reduce the ability of the door to seal properly.

What does it mean? Replacement jamb guards are required and possibly door section in the event

of damage to the door section. If jambs are replaced, then it is recommended to always replace the

door gaskets. Heater cables are located in the exterior of the door opening under the jamb guard

for most suppliers. Slide door headers are usually in the door leaf.

What could I do? Install new jamb guards ordered through walk-in supplier to fit that door; replace

door and section if damage is severe.

Examples of damaged door jambs.

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What am I seeing? Retro-fit swing door and frame. Failed door frame heaters on freezer and hinge

doors can damage the area needing a retro-fit door and facer assembly. Photo below on right

illustrates a new section and wall panels added into an existing wall.

What does it mean? The retro-fit door with a new jamb, heaters and door leaf is a rapid fix solution

for a damaged door area. Adding needed panels or a facer is a cost-effective repair method.

What could I do? Measure the door opening, surrounding panels, height and width. Verify the

colors.

Header, door and facer installed in an existing wall New door and section installed into a wall

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What am I seeing? Failed door frame heaters on freezer and hinge doors. Ice appears in different

areas.

What does it mean? Replacement of heaters isn’t always the problem. Many times, a breaker is

tripped, or the door is simply disconnected. Ice will grow around door on the walls as these photos

indicate. Some heaters are self-regulating, and some have an internal temperature control.

What could I do? Verify the heater is or is not working by verifying heater circuit has power. Check

the door adjustment and gaskets.

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A Look into a New Supercenter Under

Construction

Construction schedules are tight on new stores. Many things are going on at the same time.

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What am I seeing? A deli area going into a new supercenter. Ceiling, wall framing, and flooring

haven’t begun yet.

What does it mean? It is imperative that

the assembly process is conducted to

Walmart specifications. Sealants,

fasteners, and a dry, clean installation

site are mandatory.

What could I do? Check on jobs as they

are being installed. Communicate with

your Mechanical Services Construction

Manager any areas of concern.

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Walmart Walk-In Hinged Door Hardware

Nomenclature

Terminology Walmart Walk-In Hinged Door and Hardware Details

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What am I seeing? Proprietary Latch and Hinge designs with the associate and total cost of

ownership in mind.

What does it mean? Provides for ease of use while opening doors for all associates. The ¾” lift on

hinge at 85 degrees of open travel makes doors easier to use and maintain.

What could I do? Put these products to work in your stores. All Walmart’s supplied by HP will have

this hardware standard.

• Energy savings from doors being closed

• Safety improved Associate safety from traditional style door latches

• Maintenance increased life cycle in Service areas

• Door sweeps don’t drag and become damaged on floors

The vertical handle K-78 Latch The 3/4” lift K-61 Hinge

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“No Visible Fastener” Jamb Guard

What am I seeing? “No Visible Fastener” jamb guard assembly.

• Heavier thickness “Thermal Break” material to protect the opening

• Metal edges are recessed into the door section to eliminate exposed edges

What does it mean?

• Safety – This system eliminates the safety hazard of exposed edges and fasteners at the door opening

• Energy – It focuses the door heat at the gasket for better performance

• Maintenance – It is more durable than traditional jamb guards due to the way it embeds in the frame of the opening

What could I do? All will come standard with this application.

• It provides a much-improved look for doors exposed to the sales floor

• It is easily replaceable as a complete package or in parts

• Adds value by improving total cost of ownership

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Common Terminology for Walk-Ins at

Walmart

Walmart Walk-In suppliers share common terms and hardware devices involved with the Walmart

Walk-Ins product. Knowing terms for products is important to be able to get support or replacement

items correctly. Refer to information in this booklet when ordering parts or service.

Walk-In Panels – The individual insulated pieces of a cooler or freezer being assembled together

with the cam-lock connectors

Screed – The guiding strip under the wall panels

Service Door – The door used to load and maintain a walk-in compartment

Glass Door - The clear vertical customer access door on cooler and freezers

Leading Edge – Term for the side of a slide door that travels to closing point of door. The handle is

on leading edge side

Trailing Edge – The opposite of the leading-edge side of slide door

Strip Curtain – Plastic Strips installed in cooler or freezer service door openings to meet EISA

standards

Latch – The lever control on swing door to allow access to walk-in compartment

Hinge – The device on stationary edge of hinged service door to allow door travel to open

Sweep Assembly – The rubber/PVC wrapped piece attached to the bottom of a hinged or slide door

(on freezer doors heaters are installed in the sweeps)

Tread Plate – material (aluminum) used to cover a manufactured freezer floor

Kick Plate – the material (aluminum) attached to the bottom “48 of a slide or service door

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Cove Base – material installed around the floor to wall intersection of a walk in with an NSF edge

at floor

Class 1 Polyurethane – UL rated fire test that means another source is required for combustion.

The urethane product will not fuel itself to burn

Standard Panel Thickness – 3-1/2“ Cooler and 5” Freezers for Walmart (other thicknesses can be

available)

Panel Finish – the consistent color or finish of interior and exterior metal pans precisely roll formed

to insure proper size. These metal finishes for Walmart are Natural Galvanized Embossed on

exteriors and White Galvanized Embossed on Interior – 26 gauge

Wood Frame – A precision formed tongue and groove panel rail design joined by cam-locks at

panel seams providing superior strength and rigidity. Products are #2 or better kiln dried lumber.

Top to wall seams are typically lagged bolted together

Polyurethane Foam – the three-part mixture of isocyanate, polyol and an accelerant to create the

urethane product in Walmart Walk-In panels

Membrane Roof – a manufactured membrane roof product designed for field installation on a

walk-in. The same or very similar product to a Walmart retail store facility with a welded in place

membrane roof.

Third Party – Walmart terminology for the self-controlled freight carrier process employed to deliver

the manufactured products to Walmart locations from each respective supplier/manufacturer

Butyl – the sealant compound used on the interior of panel seams at intersections of panels and

wall/floor to panels. Butyl is installed within the seams

Silicone – the vapor barrier material used as a sealant and exterior/interior treatment at panel

intersections. Used on the exterior surfaces of panels

Batten Strip – the material used to cover panel seams with an insulated section of metal. Made of

26 gauge metal in similar color to wall or ceiling panels

Liner Panel – 2” flange joined product used to add R-value to an existing panel wall

Walmart Walk-Ins are required to meet NSF requirements for packaged foods. UL Standards are

required for electrical and flame spread ratings.

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Walmart Walk-In providers must meet certain standards in addition to EISA 2007 and DOE 2012.

The symbols here represent two of several listing and testing agencies involved with the Walmart

Walk-In product. Feel comfortable letting customers and vendors know Walmart purchases the

best products for all facets of food storage, preparation and point of sell.

National Sanitation Foundation

789 N. Dixboro Road

Ann Arbor, Michigan 48105-9723 USA

1-800-NSF-MARK / 734-769-8010

www.nsf.org

Underwriters Laboratories

2600 N.W. Lake Rd.

Camas, WA 98607-8542

Telephone: 1-877-UL-HELPS (1-877-854-377)

Fax: 1-360-817-6278


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http://www.nsf.org/mailto:[email protected]


Basic Installation Notes

• Walk-ins must be received into a dry location

• Walk-in layout area should be verified for square (One simple but effective method of

insuring the corners of any rectangle are

square is based on the Pythagorean Theorem

from geometry. The Pythagorean Theorem

holds that if the lengths of the sides of a

triangle are any multiple of five, four, and

three than one of the angles of that triangle

will be 90 degrees or square. For example: If

a triangles sides are 5 inches, 4 inches, and 3

inches, then one angle of the triangle is 90

degrees.)

• Walk-Ins must be sealed to manufacturer and Walmart specifications. Butyl on the warmest

side of vertical seams for walk-ins at 32

degrees F operating temperature or less. Butyl

at top to wall and floor to wall intersections on

all panels.

• Walk-In panels must be assembled plumb and level as the install progresses

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Basic Maintenance Notes

For further information please visit: https://kpsglobal.com/resources/installation-maintenance

Keep all walkway surfaces clean and free of spilled liquids and food particles. This includes the floor

metal surface and diamond tread plate. Wipe up all spills with warm water and mild detergent.

(control amount of water)

Never use corrosive or abrasive cleaners. Check with the manufacturer for any potential cleaning

product reaction with different metals and finishes. Caustic cleaners should never be used.

Water condensation must never be permitted to drip onto the walk-in floor. Refer to your refrigeration

system instructions for proper condensate drain line installation.

If entry doors are to be held open for extended periods of time, longer than 5 minutes, a vinyl strip

curtain should be used. Beginning 2009, all doors must have strip curtains or other means to

minimize infiltration when doors are open. When freezer doors are opened for extended periods of

time, frost can form on the walk-in.

Inspect the door hardware and sweep gasket monthly for ease of operations. The sweep gasket

must be adjusted to allow free movement and proper seal. Any damaged hardware should be

replaced immediately to prevent permanent damage to door.

Frost or condensation appearing around the door jamb or heated pressure relief vent indicates that

the electric heater is inoperable. Check the power supply (must be 115V) and electrical connections.

Always replace heaters when necessary.

Inspect the conditions of abrasive coated anti-skid strips monthly. Replace or add additional strips

when necessary. Abrasive coated anti-skid strips are factory installed on ramps. Additional strips

are available to purchase from the factory.

All metal surfaces, magnetic door gaskets and door sweep gaskets should be cleaned frequently

with a mild detergent and hot water to remove any grease and oil. Remove all soap film and dry

thoroughly with a clean cloth to prevent any ice formation. Never use a high-pressure hose or

massive amounts of water to clean walk-ins; this may cause panel seals to become damaged.

Note: If finish is stainless steel, always wipe in the direction of the material “grain”.

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Preventative Maintenance Notes

Inspect refrigeration equipment frequently for proper functioning of evaporators, drain pan heaters,

defrost controls, and drain line heaters. Refer to the manufacturers’ instructions for the

refrigeration system.

Lubricate door hinge bearings, latches, and inside releases with petroleum jelly at least once a

year.

Adjust door sweep as necessary to compensate for wear or uneven floors.

Periodically check all hardware and fasteners (attaching screws) to be sure that they are firmly

anchored. If any hardware malfunctions, see the owner’s manual for terms of warranty and act

accordingly.

Maintain unrestricted air flow across the evaporator unit and be sure the coil is kept free of any dirt

at inlet (behind usually) and outlet (typically in front). Make sure that the evaporator drain lines run

free and clear.

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Condensation and Ice Causes and Prevention

Condensation and Ice are not limited by or attributable to any specific panel type or manufacturer.

Since it is not specific to panels, research was conducted into other areas that could cause or

contribute to condensation and ice. Several contributing factors were found:

• Initial Start-Up: Many contractors responsible for the initial installation of panels and refrigeration stated the walk-ins were brought to temperature immediately. All freezers and

some coolers were directly set at below freezing temperatures. There was no temperature

draw-down process so some of the ice observed could easily have existed since the first day

of operation. The American Society of Refrigeration, Heating and Air-Conditioning

Engineers (ASHRAE) specifically addresses moisture removal through a temperature pull-

down schedule. See Engineering Specification 7140 Temperature and Draw Down

Schedule.

• Cooler Temperatures: There was water on the floor of many coolers from periodic wash down. The coolers that were kept at temperatures below freezing all had ice somewhere:

ceiling, common wall, and on evaporators. At these temperatures moisture in the coolers

will condensate on the coldest spot and freeze. The coolers that were kept at temperatures

above freezing did not have ice anywhere. Cooler temperature should be maintained above

freezing. See Engineering Specification 7100 Condensation Basics.

• Condensate Drains: If the condensate drains are not constructed properly they will allow moist air to be pulled into the freezer and the evaporator fans will then spread it on the

ceiling, shelving, product and floor where it freezes. The condensate drains observed were

in many different configurations. There were vertical offsets and individual lines were

combined before the trap; in some designs air gaps were used and were turned down and

the traps were made by combining elbows rather than actual “P” fittings. These

configurations would allow the traps to be siphoned and allow moist air to be pulled into

the freezers. 11P” traps are required in condensate lines and are to be installed outside of

walk-ins just before entering a common condensate line. Condensate drains should be

configured to eliminate siphoning and to maintain an air flow seal in the 11P” trap.

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• Defrost Process: In many freezers ice “marbles” were located on the ceiling around the evaporators. These are created from steam rising from very hot coils that have been in a

defrost cycle for too long. Some of the snowy ice on the ceiling may come from the fans

coming on too soon after defrost while the coil is still warm blowing moisture into the

freezer. Defrost time and fan delays are critical to elimination of moisture.

• Maintenance: Most of the sliding doors did not seal and again, this was not specific to manufacturer. They were not adjusted and had torn and missing gaskets. Many strip

curtains were torn, missing strips or propped up in shelving or on product. Most of the air

infiltrating around the door and strip curtain will freeze to the wall either side of the opening

and depending on the condition of the strip curtain, on the ceiling. Based on this

observation most slide doors were in need of adjustment, maintenance, and in some cases

proper installation.

• Operations: Lack of airflow was a major contributing factor. Every freezer with issues had product packed onto shelves tight to walls and stacked up to, beside, and in front of the

evaporators. In many cases it was impossible to walk into the freezers as product was

stacked solid to the door. The restricted air flow affects the temperature differential

settings at the evaporators. The product becomes cooler than the evaporator coil and

moisture (latent heat) is retained rather than removed from the freezer, the refrigeration

set points and actual room temperatures no longer agree and it freezes on ceiling, product,

and shelving. The product should be 4” away from walls and 24” away from the evaporator

in all directions.

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Installation and Maintenance Checklist

Temperature Draw-Down: New Construction or restart per specification

Walk-in temperatures Coolers above 32°F (0°C)

Freezers at or below 32°F (0°C)

Condensate Drains 1” per 10’ drop horizontal run

Straight line from evaporator to exterior – no vertical offsets

Provide “P” trap in each line outside walk-in before entering

common line

If air gap is used it must be above “P” trap

Check “P” trap seal

Defrost Process Defrost Temperature

Defrost Duration

Fan Delay

Door maintenance Door adjustment and park stop

Gasket condition

Floor guides

Strip curtain

Product Storage 411 between product and wall

24” clearance around evaporator in all directions

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Condensation Basics

Condensation is caused when the surface temperature of an object is at or below the saturation

temperature (dew point). Condensation will initially form on the coldest surface of a room. Due to

the construction of any insulated panel the exterior center of a panel will have a slightly higher

temperature than the edges. Therefore, condensation would begin to occur at the panel edge first

if the surface temperature is below the dew temperature. At recommended conditions of 75

degrees F and 55% relative humidity the dew point is 57 .8°F (see attached Psychometric Chart

Example 1) At a constant ambient temperature, the dew point will rise as the relative humidity rises. For

example at a dry bulb temperature of 75F the dew point will rise from approximately 55F to 68F

as the humidity rises from 50% to 80% respectively (See attached Psychometric Chart example 2)

Restated, even as the room temperature remains the same, warmer surface temperatures can

cause condensation as the humidity increases.

At a constant relative humidity, the dew point will rise as the dry bulb temperature rises. For

example, at a constant relative humidity of 55%, the dew point will rise from approx. 52°F to 67°F as the dry bulb temperature rises from 70°F to 85°F respectively (See attached Psychrometric Chart

Example 3). In other words, as the ambient air temperature rises, condensation can occur with warmer

surface temperatures.

There are different ways to mitigate condensation. The first is to increase air circulation. The increased

ventilation will help to dry surfaces that would otherwise have condensation forming. Another way is to

improve the conditions of the space where the condensation is occurring. Lowering the ambient

temperature and/or humidity of the space below dew point conditions for the surface temperature of the

walk-in will prevent condensation.

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FUSIONFRAME® Panel Rail Systems

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TECHNICAL SERVICES HANDBOOK September 2019 - KPS Global® · 2019. 9. 25. · 4 ©KPS Global 2019...

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Transcript of TECHNICAL SERVICES HANDBOOK September 2019 - KPS Global® · 2019. 9. 25. · 4 ©KPS Global 2019...