How to Install a Walk-in Cooler

Major industrialized food chains employ walk-in coolers to store large quantities of perishable, frozen goods. Walk-in coolers enable an increase in food production for restaurants, simply because of larger storage capacity and shorter shipment intervals. Walk-in coolers are not limited to commercial uses; customized versions exist for residential kitchens. Walk-in coolers are also installed outdoors, which frees the available floor space for indoor activities. Different models offer advanced features and benefits at varying prices. Finding the appropriate walk-in cooler necessitates a great deal of patience and capital. U.S. Cooler, a division of Craig Industries, offer state of the art walk-in cooler models geared toward self-installation.

Things You'll Need

• Walk-in cooler assembly
• Gloves for handling purposes
• Cam-lock wrench
• Caulk gun and NSF silicone caulk
• Electric power drill with a Phillips driver and 1/8-inch drill bit
• Rivet gun
• Stainless steel screws (provided)
• Metal plate
• L-shaped metal bracket
• Vinyl tarp
• Evaporator coil
• 1/2-inch metal drill bit
• Refrigeration system

Instructions

Foundation Installation

1. Locate the 'F1' floor panels, and assign the units according to the floor plan drawing. Lock each numbered floor panel with each interlocking tongue and groove counterpart. Next, align the edge of the floor panels flushed against each corresponding panel. Insert the cam-wrench into the cam-lock holes and turn clockwise thoroughly until unable to go further. Do not torque the cam-wrench past stop.

2. Lock each numbered floor panel with each interlocking tongue and groove counterpart.

3. Align the edge of the floor panels flushed against each corresponding panel.

4. Insert the cam-wrench into the cam-lock holes and turn clockwise thoroughly until unable to go further. Do not torque the cam-wrench past stop. Repeat for each of the remaining floor panels until fully assembled.

Floorless Installation

1. Using chalk, delineate the area of the boxed walls according to the enclosed plans. An even square should cover the dimensions of the screeding area. Overestimate the boundaries by 1/2 inch for screeding oversize.

2. Caulk two beads within the 4-inch wall boundaries. Seal the edge of the screeding to the metal finish with NSF silicone caulk.

3. Gather the 'W1' and adjacent wall panels to form the first corner. Align the 'W1' and adjacent panel according to the screeding outline for floor-less plans. 'W1' wall panels interlock vertically in tongue and groove with the floor units. Ensure all arrow diagrams adhere to its manufactured design, which points downward.

4. Connect the 'W1' and 'W2' wall panels flushed evenly together.

5. Insert the cam-wrench into the cam-wrench holes on the 'W2' wall panel. Secure the wall panels by turning the cam-wrench clockwise thoroughly until it fully stops. Just as with the floor plan, do not torque the cam-wench too aggressively. Test to see if the wall panels interlock firmly.

6. Continue installing until each wall panel becomes fully erect. Adjust the wall until each higher numbered panel aligns flush to the floor plans. Disassemble the door from the frame until installing the latter incurs.

Entranceway Installation

1. Install a threshold down bar from the floor panels at the point of door installation.

2. Direct the hooks of the threshold down bar in the same fashion as the cam slots. The threshold bar hooks should make contact with the cam pins.

3. Tap the threshold bar in the direction of the cam pins and hooks until it ceases progress.

4. Continue to install the remaining wall panels.

Ceiling Installation

1. Gather the 'C1' ceiling panel, and align it evenly according to the enclosed drawing. Adjust any disproportionate panels before proceeding.

2. Lock all cams with the cam-lock wrench. 'C1' ceiling panel tongue interlocks with 'C2' groove to create a sturdy walk-in topside.

3. Continue to install each corresponding ceiling panel in numerical order.

Tweaking the Doorway

1. Close the walk-door after the installation of all panels, and verify if the door aligns flush with remaining unit.

2. Shim the leg of the door frame if an increase or decrease reveals across the top of the doorway. Unlock the cams around the perimeter of the frame, adjust the door leg, and relock the cams to meet the desired outcome.

3. Screw the threshold bar onto the floor panels with the stainless steel screws provided with the unit. Attach an L-shaped bracket to support floor-less designs.

4. Use NSF silicone caulk to seal in the perimeter for better insulation.

Rain-Proofing Installation

1. Install an evaporator coil and caulk around the carriage bolts before installing the rain roof. Spread vinyl roofing material across the walk-in topside. Allow 6 inches of the vinyl to overlap each side. Unravel the vinyl flaps until thoroughly positioned.

2. Screw a stainless steel screw through a metal plate in the middle and end of each flap. Continue to roll out the vinyl and screwing down the remaining flaps until firmly secured. The vinyl should overlap the end by at least 6 inches.

3. Fold the overhangs and secure them with a stainless steel screw. Cut off the excess vinyl after this initial step.

Refrigeration Installation

1. Set the refrigeration system over a notched wall panel with a mounted side compressor. Drill through the wall with a 1/2" drill bit and bolt with the provided bolts.

2. Place the refrigeration system in the hole mounted to the topside of the walk-in unit.

3. Caulk around the perimeter of the refrigeration unit.

Tips & Warnings

• Verify the bill with the skids shipped.

• Wear gloves when handling the panels.

• Report any damages or missing parts with the trucking company before signing the invoice.

• Locate the instructional manual and provided parts.

References

• U.S. Cooler: Walk-In Coolers and Freezers