Cold Storage – TN

Keeping Operations Moving During a Tennessee Freezer Expansion

A Tennessee cold storage facility expanded to support continued growth and increase freezer capacity while existing operations remained active. The project called for 34,111 square feet of insulated panel coverage and a construction sequence that could isolate completed areas for turnover before the entire build reached Substantial Completion.

• A long working history with PermaTherm gave the project team confidence in the panel system before construction started.
• The new enclosure had to support low-temperature operations while fitting a phased build plan that brought individual areas online as work progressed.
• The installer was already familiar with the system, which reduced the learning curve and helped the panel scope move smoothly through construction.

PHF43 Panels Supported Phased Construction

PermaTherm supplied PermaCore PHF43 Light Mesa panels in Polar White. The PolyIso core and concealed-fastener assembly provided one coordinated enclosure system for the expansion, while the panel format supported the project team’s phased installation plan.

• Current PHF43 product data lists an R-value of R-8.2 per inch of thickness, supporting stable low-temperature conditions across the new freezer areas.
• When a minor issue appeared after freezer racking was installed, PermaTherm supplied replacement panels so the affected area could be corrected without delaying the broader schedule.
• The project team also documented future thermal-break considerations at the wall base, including a pre-cut detail or a less conductive C-channel to further limit thermal bridging and corrosion risk.

Additional Freezer Capacity Before Substantial Completion

The expansion was completed in November 2025, but its operational benefit began earlier. Because completed areas could be isolated and turned over in phases, the owner maintained operations, increased productivity, and brought an additional freezer online before the full project reached Substantial Completion.

• Phased turnover gave the facility usable cold storage capacity during construction instead of waiting for every area to be finished.
• Some ice buildup remained between the mechanical system and paneling at the time of the original case study. The project team expected the condition to resolve once the loading dock was fully sealed, conditioned, and acclimated.
• PermaTherm’s responsiveness during field coordination helped the installer address issues as they appeared while keeping the expansion moving.

Planning a phased freezer expansion? Talk to a PermaTherm panel expert.