Cold storage facilities are essential for preserving temperature-sensitive products such as food and pharmaceuticals, which are vital to global supply chains. As demand for cold storage continues to surge – driven by the rise of grocery delivery services, expanding e-commerce, and the growing need for medical storage – developers and owners must prioritize proper design to address the specific challenges posed by the roofing system. The roof is the area of the building envelope with the greatest potential to affect long-term performance of the facility.

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A high-performance roof is an interdependent system of materials that includes roof membranes, layers of high R-value insulation, and air and vapor barriers. Functioning as a system, the roof is critical in controlling temperature, preventing condensation, and improving energy efficiency. 

With modern insulation materials like polyisocyanurate (polyiso), cold storage facilities can improve their energy efficiency, cutting operational costs while ensuring the safety and integrity of stored goods.

Integrating advanced technology and automation can also support the performance of building envelope materials by enabling real-time monitoring and control of parameters like temperature, humidity, and energy usage. 

Leveraging building science and technology can help builders, buyers, and owners of cold storage facilities optimize both performance and costs.

Maintaining Consistent Low Temperatures

Cold storage facilities must maintain internal temperatures between 40°F and -50°F, depending on what will be stored in the facility, to ensure that all items – whether perishable foods or temperature-sensitive pharmaceuticals – are preserved in optimal conditions. The ability to precisely regulate these low temperatures is critical.

Modern insulation innovations allow for polyiso to perform even better at colder temperatures, making these formulations ideal for cold storage applications where the assembly is exposed to cold year-round. Standard roofing polyiso historically has a physical property limitation that, when exposed to cold temperatures, will result in lower-than-expected insulation R-values. Some manufacturers of polyiso have innovative formulations to reverse this property and increase insulation R-value in colder temperatures. Elevate™ ISOGARD™ polyiso is an example of this innovation and is ideal for cold storage applications, offering superior thermal performance. ISOGARDs high R-value of 6.2 per inch at 40°F mean temperature can help the facility meet stringent thermal requirements. Elevate ISOGARD™ provides up to 40% better thermal performance* at colder mean temperatures compared to other insulation options on the market, which translates into greater energy savings and long-term reliability. Beyond choosing the best insulation for the job, it is important to ensure the insulation is installed with best practices in mind. Good design and installation practice is to use multiple layers of ISO in a staggered layout to minimize air movement within the roofing system.

* The thermal performance of ISOGARD polyiso insulation is up to 40% better than major competitors when tested by an independent third party in cold temperature 40°F (4°C) applications according to ASTM C1289 standards. The increased R-value per inch means better thermal performance from the same roofing systems using the same amount of insulation compared to leading competitive products on the market today.

Meeting Growing Demand for Cold Storage Facilities with Faster Installation

The demand for cold storage facilities continues to rise, and meeting this growing need requires roofing systems that not only perform well but can also be installed efficiently. Thermoplastic polyolefin (TPO) single-ply roofing membranes have become a popular choice due to their combination of high performance and ease of installation.

Products like Elevate UltraPly™ TPO SA allow contractors to install roofing systems up to four times faster than conventionally adhered systems that require manually applied adhesive. Third-party testing has shown that UltraPly™ TPO SA can reduce labor hours for membrane installation by up to 77%. This time-saving solution helps contractors keep up with the growing demand for cold storage roofs without sacrificing quality or performance. This expedites new construction timelines, helping cold storage facilities open and generate revenue more quickly.

Additionally, self-adhered TPO systems tend to have lower concentrations of volatile organic compounds (VOCs), meaning contractors can re-roof an existing facility with minimal disruptions to building operations and personnel.

Preventing Condensation in Cold Storage Roofing Systems

One of the greatest challenges that designers face when designing new roofs for cold storage facilities is preventing vapor drive, which can lead to condensation. Condensation occurs when the moisture content of air reaches saturation, otherwise observed as when warm, wet air is cooled to its dew point and becomes a liquid. Vapor drive in roofing assemblies refers to the movement of vapor molecules from areas of high pressure to areas of low pressure, which typically is moving from warm to cold. If the design of the roofing assembly allows vapor to be driven towards the cold interior surfaces of the roofing assembly, condensation may occur. To properly prevent condensation from vapor drive, designers should understand the variables involved, such as building location and climate, the design temperature of the facility, and the inclusion of vapor retarders and air barriers in the roofing assembly. 

Air movement inside of a cold storage roofing assembly may also lead to condensation since all air inherently contains moisture. It is critical to use standard practices to install materials in a roofing assembly to prevent gaps, cracks and pockets of air space. Unintended airspace built into the assembly increases the chances of condensation. The buildup of condensation in the assembly may lead to mold, damage to roofing and structural materials, and reduce the insulation efficiency, increasing energy costs. 

Air sealing is crucial to prevent condensation. A well-designed roof assembly must include effective air and vapor barriers to prevent vapor from entering the assembly from the exterior and degrading the structure. High-performance insulation products like Elevate ISOGARD™ polyiso are key in stopping air movement and reducing the risk of condensation inside the roof assembly. This prevents mold growth and maintains energy efficiency to help preserve the facility’s long-term performance.

Leveraging Technology and Automation for Cold Storage Efficiency

Incorporating technology and automation into cold storage facilities allows for real-time monitoring and management of critical environmental factors like temperature, humidity, and energy consumption. This allows facility managers to monitor conditions 24/7, responding immediately to any fluctuations that could jeopardize product quality.

Automated systems also enable facility managers to optimize energy use. These systems can regulate temperatures based on specific storage needs, ensuring that energy is only consumed when necessary. When combined with high-performance roofing and insulation systems, automated systems maintain a thermal chamber for cold storage.

The combination of advanced technology and innovative building materials reduces operating costs and the environmental impact of a cold storage facility, allowing refrigeration and HVAC systems to do their jobs more efficiently and for longer periods of time.

The Expertise to Elevate Your Cold Storage Facility

Elevate commercial roofing systems have already been installed on over 20 million square feet of cold storage facilities across North America. Plus, partnering with a certified installer like an Elevate Master Contractor ensures that roofing and insulation systems are installed according to the specific needs of each cold storage facility. With the industry-leading Elevate Red Shield™ Limited Warranty offering comprehensive coverage of up to 30 years, you can have peace of mind for years to come.

Facility developers and owners should partner with Elevate – plus trusted manufacturers of HVAC and automated building monitoring and management systems – to ensure their cold storage facilities achieve maximum efficiency, durability, and compliance.