The Challenge

To construct a new processing environment with adjacent support areas for the purpose of the procesing and the large scale production of ready-made food products. The new processing environment and support areas needed to be designed, erected and be self contained in an existing building with limited structural capabilities. Other challenges existed in the intergration of the existing infrastructures and in ensuring full containment in order to ensure quality control and prevent any possibility of cross contamination of commodity and processes.

The Concern

Provide a hygienic interior finishes that would perform as the primary barrier, be capable of being structurally sound, load bearing, self supporting and applicable to the construction of additional spaces to suit user requirement that maintain the same finish and performance criteria.

The new wall and ceiling surfaces needed to be ultra hygienic, non-porous, impact and chemical resistant. Critically, the composite panel surfaces needed to withstand a rigorous sanitation regimen and high pressure washdowns.
Accessibility to the interstitial space (plenum) for regular maintenance were issues of great concern as well as addressing USDA compliance and regulations concerning local and state building codes.

Finally, the proposed construction needed to be completed in record time – enabling the early start-up, Q&A program certification and full production capabilities on schedule.

The Solution

Build a “box within a box” concept utilizing Arcoplast’s insulated load bearing partitions for the dividing walls between production and infrastructure spaces.

The holding freezer area utilized Arcoplast’s free standing partitions featuring a composite fiberglass reinforced insulated panel construction. The Arcoplast wall liner panels were used to re-surface existing walls, and also to clad the erected steel studs in support areas, such as the gowning and lavatory areas.

The concern over maintenance issues in the interstitial space was resolved with an Arcoplast walk-on ceiling system. It was attached to steel girths supported by the exterior steel structure and the load-bearing partition that resulted in a full span void of structural and support columns.

The existing building’s structural columns at the peripheral walls were covered with Arcoplast’s fiberglass insulated beam covers, thus eliminating costly maintenance issues as well as preventing potential contamination generated by difficult areas to sanitize and decontaminate.

The antimicrobial, non-porous, non-shedding gel coat made easy eye detection of possible surface contamination. This premium surface finish withstands high pressure wash in daily sanitation and decontamination regimen while maintainimg its permanent white high gloss finish and resistance to chemicals for long term performance.

The panels are manufactured in large flat molds and cut into large dimension maximizing the reduction of exposed joints. The dimensionally large panels are fastened to the floor or curb section, and at the ceiling height junctions. From there, the mechanical fasteners are concealed and the field of the panel is adhered with structural adhesives, thus eliminating the need for exposed fasteners. Minimal joints, devoid of exposed fasteners, coupled with a structurally sound composite panel made Arcoplast an ideal choice for contamination controlled environments in the food processing industry.

The Arcoplast cement core composite wall liner panels met the ASTM E 84 flame spread and smoke development required by local and state building codes. The insulated load bearing and free standing partitions and walk-on ceiling panels covered each side with a thermal barrier addressed Article 2603.5.2 of Chapter 26 of the International Building Code 2003.


  • Improved environmental safety with Arcoplast composite panels while incorporating thermal barriers.
  • Reduced risk of environmental and commodity contamination with air-tight and leak-tight panel construction systems.
  • Arcoplast wall and ceiling surfaces withstand repeated sanitation and decontamination procedures.
  • Reduced the costly and nonproductive downtime frequently generated by mandatory surface maintenance due to the harsh processes.
  • Arcoplast antimicrobial surfaces supplement established hygiene practices and help fight against surface microbial contamination.
  • Long term performance resulting in lower life cycle cost.
  • Exceptional design flexibility in both existing and new construction.