Hybrid Construction of Large Walk-In Unit Results in Savings for N.C. Restaurant

What-a-Burger Sign

The East Coast manufacturing facility of Imperial Brown® recently built a large
freezer/freezer combo unit for Whataburger restaurant in Concord, NC, using its new
hybrid construction method.
To construct the 47’ long combo unit, the designers combined 5½” wood frame
construction ceiling panels in the 47’ long combo unit, along with low-density
construction in some wall panels, for a cost-effective solution for the customer. Hardnose
panels can span up to 25’ without roof support, contributing to less factory time
and more real estate inside the unit. Low-density panels only span up to 15’.
The hybrid method reduced the number of ceiling panels needed in the project,
according to Robert Wolfe, Designer for Imperial Brown.
Four-inch high-density construction was also used in wall panels that required
customization. “This method was the most cost effective,” Wolfe said. “The
Production Department would have had to build additional panels to get the
customization with the low-density method.”
Imperial Brown is the only manufacturing facility in the country with the ability
to produce hard-nose/soft-nose combination units, a distinct price and technical
advantage to customers.
Hybrid construction gives the factory complete flexibility to build coolers of any
shape or size, resulting in a stronger, consistent product with a more efficient production time, a lower materials cost and a higher
overall R-rating. Advantages include:
• Exact dimensions to maximize space
• Notches and angles around wall and ceiling
• Greater height and spanning, unsupported
• Door placement at the corner (soft-nose
requires 11”-12”)
• Uses lower cost soft-nose construction where
customization is not required
• Uses hard-nose panels only where required
• Hard-nose floors provide the greatest
structural support for performance and
integrity over the life of the walk-in unit
Whataburger’s 47’ long freezer/freezer unit is 20’2” deep. One of the freezers is 23’8” long and the other is 23’4”. It is
8’ 9½” tall. The factory also built a smaller cooler unit for the customer that is standard 11’7” by 7’9” and 8’ 7¼” tall. It was
constructed of low-density panels.
Yarbrough Refrigeration of Concord, NC was the customer for this project.