Insulated Metal Panels Pose Risks for Cold Storage Buildings

Roofing expert warns of common issues with insulated metal panels that can lead to ice buildup and other problems in freezer facilities

Mar. 21, 2026 at 7:35pm

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Roofing expert Thomas W. Hutchinson discusses the challenges of using insulated metal panels (IMPs) in cold storage buildings, such as freezers operating at -20°F. He highlights common issues like improper sealing of panel joints, uneven panel heights, and poorly designed scuppers that can allow warm, moist exterior air to infiltrate the interior space, leading to ice buildup and other problems. Hutchinson provides recommendations for addressing these problems, including detailed sealing techniques and ensuring level panel installation.

Why it matters

Insulated metal panels are a popular choice for cold storage buildings due to their built-in insulation and ease of installation. However, if not properly designed and installed, these panels can create significant issues that compromise the building's thermal performance and lead to costly repairs. Understanding the common pitfalls and best practices for IMP usage in freezer facilities is crucial for building owners, designers, and contractors to avoid these problems.

The details

Hutchinson explains that the main issue with IMPs in cold storage is the natural drive for warm, moist exterior air to mix with the frigid interior air, leading to ice buildup. He notes that many designers and installers fail to properly seal the panel joints, both on the exterior and interior, allowing air infiltration. Uneven panel heights also prevent the top metal cap from sealing tightly, creating additional pathways for air movement. Poorly designed scuppers can further exacerbate the problem by providing direct openings for exterior air to enter the building.

  • Hutchinson has been called to investigate roof failures in cold storage buildings for many years.

The players

Thomas W. Hutchinson

A principal of Hutchinson Design Group Ltd. in Barrington, Illinois, and a member of Roofing's editorial advisory board.

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What they’re saying

“I have never opened up a cold storage building roof in which the insulation was not full of ice or the interior with substantial ice (see photos 1, 2, 2a and 2b)!”

— Thomas W. Hutchinson, Principal

“The most important concept for designers and then the construction team to fully understand is a law of physics that they cannot change: 'Energy high to low' 'Air wants to meet an equilibrium.'”

— Thomas W. Hutchinson, Principal

What’s next

Hutchinson plans to address additional topics related to cold storage building design and construction in future articles.

The takeaway

This article highlights the critical importance of properly sealing and installing insulated metal panels in cold storage facilities to prevent air infiltration and the resulting ice buildup, which can lead to significant operational and safety issues. Designers, contractors, and building owners must work together to ensure best practices are followed to avoid these common problems.