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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
682.317.5378 [email protected]
Tom Beatty Vice President of Construction
Junior Burnside Sr. Director of Construction Services
Jason Bratcher Director of Construction Services
817.965.1296 [email protected]
Chris Stewart Installation Manager
682.317.5317 [email protected]
Mike Odle Service Manger
682.317.5430 [email protected]
Kevin Stone Turnkey Manger
940.366.5362 [email protected]
Barry Walsh Project Manager
817.614.4315 [email protected]
Don Davis Project Manager
972.836.4690 [email protected]
Barry Beard Project Manager
940.315.0534 [email protected]
Randy Wolf Project Manager
972.979.6536 [email protected]
Jeremy Boatner Project Manager (Sam’s Club)
817.602.8154 [email protected]
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
s Info
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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
Walk-In
s Info
rmatio
n
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
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http://www.jamisondoor.com/mailto:[email protected]
©KPS Global 2019 11
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]
Walk-In
s Info
rmatio
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https://frankdoor.com/Slide-Single-Doormailto:[email protected]
©KPS Global 2019 12
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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©KPS Global 2019 13
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
Walk-In
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©KPS Global 2019 14
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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©KPS Global 2019 15
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
Walk-In
s Info
rmatio
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mailto:[email protected]://www.thermoseal.com/
©KPS Global 2019 16
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
Email: [email protected]
www.styleline.com
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mailto:[email protected]://www.styleline.com/
©KPS Global 2019 17
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.
Walk-In
s Info
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©KPS Global 2019 18
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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http://www.chasedoor.com/
©KPS Global 2019 19
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
Walk-In
s Info
rmatio
n
http://www.chasedoors.com/http://www.kasonind.com/
©KPS Global 2019 20
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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©KPS Global 2019 22
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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©KPS Global 2019 23
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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©KPS Global 2019 24
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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©KPS Global 2019 25
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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©KPS Global 2019 26
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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©KPS Global 2019 27
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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©KPS Global 2019 28
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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©KPS Global 2019 29
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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©KPS Global 2019 30
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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©KPS Global 2019 31
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.
Walm
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©KPS Global 2019 32
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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©KPS Global 2019 33
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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©KPS Global 2019 34
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
Email: [email protected]
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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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