How to Assemble a Walk-In Cooler: A Step-by-Step Guide

Assembling a walk-in cooler is easier than most people expect. With the right prep, two or three people and just three hand tools, you can put together a commercial walk-in yourself, with no power tools required. We teamed up with David Phillips of Premier Food Service Group, the Amerikooler reps, to build an Amerikooler walk-in right on the floor of our Norcross, GA showroom. Here's how it's done, step by step.

Tools You'll Need

You don't need power tools to assemble an Amerikooler walk-in. All you need is:

• Cam key: included in the box with your Amerikooler walk-in
• Mallet: to tap in the button plugs
• Level: to check the floor and keep panels even

Plan on two to three people for the build. Panels are large, and the refrigeration unit is heavy.

Before You Build

1. Measure Your Space

Before you build anything, go into the space and measure it to make sure the walk-in will fit. One of the most common problems is building a box only to find out the space isn't big enough. Measure first, and measure again.

2. Inspect Your Delivery

When your walk-in arrives, inspect it all the way around for damage, including forklift damage or general shipping damage, before you sign off on the delivery.

3. Find the Parts Box

Locate the box packed inside the walk-in shipment. It holds your key components:

• The drawing (your assembly layout)
• The button plugs
• The cam key

4. Stage the Panels

Don't unload panels directly into your work area. Stage them nearby, leaning them gently against a wall. Panels can be damaged if they're handled roughly, so take your time.

Step-by-Step Assembly

Step 1: Level the Ground and Set the Floor

The floor panels go down first. Before setting them, use your level both horizontally and vertically to make sure the ground is level.

• Work from back to front. Always start setting the floor at the back.
• Leave a 3-inch air gap between the walk-in and the surrounding walls. This helps prevent condensation and mold from building up on the exterior wall.
• Cam lock the panels together. Bring the panels together and make sure they're level top to bottom and side to side, then turn the cam key gently.

Step 2: Build the Walls

Wall panels go up the same way as the floor, from back to front, but always start in a corner. Your first piece will be either the back-right or the back-left corner panel.

• Check that the corners are flush. Run your hand along the outside of the corner panel to make sure it's even, then cam it together.
• Cam the walls together first. Lock all the wall panels to each other as you go, and wait to lock the walls to the floor until the end. You can cam from the top down or from the bottom up.
• Keep the tops even. Make sure the top of each wall panel lines up with the one next to it.

Step 3: Install the Door

The door is the last wall piece to go in. To make it easier, leave one wall panel off, set the door section in place, then slide the next wall panel in after it.

Step 4: Lock the Walls to the Floor

Once the floor and all the walls are up, go back around the entire box and cam lock the walls to the floor. Listen for that bite on every cam.

Step 5: Set the Ceiling

The ceiling works just like the walls. Set the back panel first, and work forward. Make sure each ceiling panel is even with the wall on the outside and doesn't stick out or sit in. A flush fit is what gives you a proper seal.

Step 6: Install the Refrigeration Unit

With the ceiling in place, it's time to set the refrigeration unit. The unit is very heavy, so we strongly recommend using a duct jack to raise it. Jack it up slowly, then have two people on top of the walk-in lift it and set it into the ceiling cutout.

Step 7: Finish Up: Door Sensor and Button Plugs

Once the box is fully assembled:

• Mount the door sensor.
• Install the button plugs. Every cam hole needs a button plug. Tap each one in with your mallet. The plugs keep condensation from building up inside the walk-in.

Quick-Reference Checklist

• Measure the space before ordering and building
• Inspect the delivery for damage
• Find the parts box: drawing, button plugs and cam key
• Stage panels carefully away from the work area
• Level the ground, horizontally and vertically
• Set the floor back to front with a 3-inch air gap
• Build the walls from a back corner, keeping the tops even
• Install the door, then lock the walls to the floor
• Set the ceiling back to front, flush with the walls
• Lift the refrigeration unit with a duct jack
• Mount the door sensor and plug every cam hole

Frequently Asked Questions

Do I need power tools to assemble a walk-in cooler?

No. An Amerikooler walk-in goes together with just a cam key (included), a mallet and a level.

How many people does it take to build a walk-in?

We recommend two to three people. You'll need at least two on top of the box to set the refrigeration unit.

Why do I need a 3-inch gap around the walk-in?

The air gap between the walk-in and the surrounding walls helps prevent condensation and mold from building up on the exterior wall.

What are button plugs for?

Button plugs seal the cam holes in each panel. Every cam hole needs one to keep condensation from building up inside the walk-in.

How do I know a cam lock is secure?

Listen for the "bite," a crunch you hear when the cam hook latches onto the next panel. That sound tells you the panels are locked correctly.

Find the Right Walk-In for Your Space

Not sure what size or configuration you need? ACityDiscount's walk-in specialists will help you find the right fit for your kitchen and application, whether you need a stock size or a custom build.

• Call for a quote: 404-752-6715
• Shop: Amerikooler walk-in coolers and freezers
• Visit: See a fully assembled Amerikooler walk-in in our 60,000 sq ft showroom at 6286 Dawson Blvd, Norcross, GA

Special thanks to David Phillips and the Premier Food Service Group team, and to Amerikooler, for their partnership on this guide.