Looks were important, but performance was paramount. By utilizing factory-insulated metal roof and wall panels from Kingspan Insulated Panels for the construction of a new wine storage facility, a California contractor was able to give his Napa Valley winemaking client a building that was not only attractive, but also perfectly suited for its very specific purpose.

The Chappellet Winery is located on a remote wooded site on picturesque Pritchard Hill, near St. Helena. From its location, almost 1,300 feet up on the mountain, visitors can look out on Lake Hennessy and the beautiful scenery of Napa Valley. The winery’s second-generation family operators were sensitive to the impact any new construction might have on the natural surroundings but they also needed to expand storage capacity, leading to the decision to build a new 30,000 sq. ft., temperature-controlled wine aging room, known in the wine making industry as a barrel chai. The planned structure would be large enough to store 4,000 barrels and include both a barrel wash area and a small 20-tank white wine production space. Once complete, the new barrel chai would enable conversion of the previous aging room into a space for the winery’s popular tasting tours.

Division 13 Buildings, Inc., of Windsor, California was the design build metal building contractor on the project, which is on track to achieve LEED Gold certification. “The Chappellet Winery storage facility project was a pre-engineered metal building structure,” said Marc Davis, president and owner of Division 13 Buildings. “Because of previous successful projects, it was decided to use Kingspan insulated metal panel products on both the roof and walls.”

The Critical Top

According to Davis, KingZip^™ panels were specified for the roof system because the standing seam insulated metal roof panels provided the energy performance needed for the project. KingZip^™ roof systems can result in energy savings of as much as 30% over conventional cavity-based insulation systems due to a high R-value, superior airtightness, and low thermal bridging. “The KingZip^™ standing seam insulated metal roof panel provides great looks and incredible energy performance,” he said. “Simply stated, it's a superior commercial metal roof system.

“The design also called for the entire roof of the barrel chai to be covered in solar panels,” said Davis. “The Kingzip^™ panel made attachment very easy.” In total, approximately 25,000 square feet of Kingzip^™ roofing panels, in six-inch thicknesses, were installed to create the roof system.

The Working Walls

One of the biggest sources of heat loss or gain in a building is due to air leakage. While KingZip^™ metal roofing panels will protect the top of the building from both air and water infiltration over the life of the structure, Kingspan wall panels will play a big role in the integrity of the building envelope too. The storage building features approximately 8,750 square feet of Kingspan 300 Minor Rib panels in 2”, 3”, and 5” thicknesses, and 6,500 square feet of Kingspan 3” thick 400 V-Wave panels.

The 300 Minor Rib foam insulated metal panel allows flexibility in design and can be used in many differing building types. It minimizes construction delays by offering a single component insulated metal panel product instead of more complicated multi-part foam insulated panels. The 300 series panel was used on two sides of the fascia to provide insulation and a single skin CorTin panel was installed over the outside face as an architectural finish.

300 series panels were also used on several interior walls. The insulation value and the imperial white finish on both sides of the panels made an attractive building interior. The 400 V-Wave foam insulated panels also give designers flexibility and can be used in multiple building designs.

Practically Attractive

All series of insulated metal panels offered by Kingspan give walls excellent thermal performance and, as an added benefit, greatly increase a building's curb appeal with an impressive look.

Kingspan 400 V-Wave and 300 Minor Rib insulated metal panels were used on the walls and fascia primarily as an insulating product, but also because they offered a look that added to the winery’s pastoral appearance.

“When there is a need for a high R value system, or a system that will perform well in a humid environment, the Kingspan IMP is the product of choice,” Davis said. “But for this project in particular it was also important that they give the barrel chai structure the impressive look the owner desired.”

As an experienced metal building contractor, Division 13 Buildings, Inc. has built many types of structures. Davis noted that over the years, insulated metal panels (IMPs) have proven to be a superior product, especially for the needs of the winery industry. He is very impressed that KingZip’s one-step installation can reduce on-site installation time compared to conventional roof systems.

“There were several unique features Division 13 performed on this project due to the special needs of a winery and compounded by its location in an area of high humidity,” said Davis. “The Kingspan products were well suited to these environments and performed far better than other products.”

Davis observed that many more construction projects would utilize Kingspan IMPs. “In my opinion, Kingspan products will continue to become a desired cladding material on commercial buildings in this region in the future,” he said. “The main benefits of specifying Kingspan insulated metal panels are insulation value, durability, architectural appeal, and ease of installation.”