Air Sealing The Impact on Home Rating and Energy Savings
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1 Air Sealing The Impact on Home Rating and Energy Savings Kate Johnson Dow Chemical Company February 24, 2010
2 Presentation Outline Focus: Air Leakage Toolbox Boundary Conditions Process Case Studies Effectiveness and Payback
3 Houses leak?!
4 Current Situation 80 MM detached homes in US Source DOE
5 Payback: 6 months* ROI at 7 years 1,400% Payback = CFL cost/annual electricity savings, estimated CFL Lifetime is claimed to be 7 years
6 Payback: 4 months* ROI at 7 years 3,400% Payback = material cost/annual heating & cooling savings Calculation based on all homes in study, averaged
7 Common Sources of Air Leakage Pipe/HVAC penetrations
8 Common Sources of Air Leakage Pipe/HVAC penetrations Windows & Doors
9 Common Sources of Air Leakage Pipe/HVAC penetrations Windows & Doors Attic hatches
10 Common Sources of Air Leakage Pipe/HVAC penetrations Windows & Doors Attic hatches Garage/house walls
11 Common Sources of Air Leakage Pipe/HVAC penetrations Windows & Doors Attic hatches Garage/house walls Open floor joists
12 Common Sources of Air Leakage Pipe/HVAC penetrations Windows & Doors Attic hatches Garage/house walls Open floor joists Cantilevered bay windows
13 Common Sources of Air Leakage Pipe/HVAC penetrations Windows & Doors Attic hatches Garage/house walls Open floor joists Cantilever bay windows Electrical outlets
14 Common Sources of Air Leakage Pipe/HVAC penetrations Windows & Doors Attic hatches Garage/house walls Open floor joists Cantilever bay windows Electrical outlets Rim Joist
15 Hypothesis Air sealing with one/two component spray foam sealants is a fast, low cost, effective way to reduce air leakage applicable to existing homes with a broad age range
16 Home Selection
17 Boundary Conditions 1 day Accessible Pre-screened Air sealing materials
18 Study Details 15 existing homes 1926 and 2001 Michigan, Indiana, and Ohio Limited to air sealing and testing in one day using One/Two Component Foam Measurement of time/material/location Blower door test before and after each change REM/Rate calculations to estimate annual energy savings attributed to reduced air leakage
19 The Toolbox
20 Cost Effective Materials
21 Cost Effective Materials Two Component Foam Large coverage area Thicker foam Offers insulation (R-value) Fast-cure Self-contained kit
22 Cost Effective Materials Two Component Foam Large coverage area Thicker foam Offers insulation (R-value) Fast-cure Self-contained kit
23 Cost Effective Materials Two Component Foam Large coverage area Thicker foam Offers insulation (R-value) Fast-cure Self-contained kit One Component Foam Small coverage area Slightly slower cure Smaller container No mixing nozzle Various expansion formulas
24 Cost Effective Materials Pro 20 oz Consumer 12 oz Two Component Foam Large coverage area Thicker foam Offers insulation (R-value) Fast-cure Self-contained kit One Component Foam Small coverage area Slightly slower cure Smaller container No mixing nozzle Various expansion formulas
25 Code Status of Materials Exposed up to 2 in rim joist Thermal barrier other locations Exposed up to 34 in²/sf of wall area Fireblock orange color
26 Process Visual inspection Baseline blower door test at -20, 30, 40, 50 Pa Assessment Select location/product Prepare location, install, record time/amount of material Second blower door test Continue with subsequent locations Input into REM/Rate to calculate expected heating and cooling energy use and cost of initial air leakage rate and subsequent air leakage
27 Find the leak
28
29
30
31 Case Study #1 Built in 1926 Balloon Framing
32 95 linear feet of rim joist 100% accessible Rim Joist
33 2.5 cans Pro G&C with gun applicator 1.75 hours labor Sill plate Batt insulation was removed and replaced after sealing
34 Air Leakage at 50 Pa (cfm) Rim Joist Air Leakage Reduction Baseline Rim Joist Case Study #1 What was done: 95 linear feet of rim joist Product used: 2.5 cans G&C Pro with gun applicator Labor: 1.75 hours
35 Air Leakage at 50 Pa (cfm) Rim Joist Air Leakage Reduction Baseline Rim Joist Case Study #1 What was done: 95 linear feet of rim joist Product used: 2.5 cans G&C Pro with gun applicator Labor: 1.75 hours Initial HERS Score 190 Initial 50 Pa After sealing rim joist 182 ACH after sealing rim joist 20.14
36 Rim Joist Air Leakage at 50 Pa (cfm) Air Leakage Reduction Baseline Rim Joist 13% Air Leakage Reduction What was done: 95 linear feet of rim joist Product used: 2.5 cans G&C Pro with gun applicator Labor: 1.75 hours 3000 Case Study #1 Initial HERS Score 190 Initial 50 Pa After sealing rim joist 182 ACH after sealing rim joist HERS Score reduced 8 points!
37 Cantilevered bay window 1/4 can of Pro G&C foam sealant and 10 minutes
38 Bay Window Cantilever Air Leakage Reduction What was done: Exterior sealed Product used: ¼ can Pro Gap & Crack with gun applicator Labor: 10 minutes Air Leakage (cfm) at 50 Pa Baseline Rim Joist Bay Window Case Study #1
39 Bay Window Cantilever Air Leakage Reduction What was done: Exterior sealed Product used: ¼ can Pro Gap & Crack with gun applicator Labor: 10 minutes Air Leakage (cfm) at 50 Pa Baseline Rim Joist Bay Window Case Study #1 Initial HERS Score 182 Initial 50 Pa After sealing rim joist 182 ACH after sealing rim joist 20.03
40 Bay Window Cantilever What was done: Exterior sealed Product used: ¼ can Pro Gap & Crack with gun applicator Labor: 10 minutes Air Leakage (cfm) at 50 Pa Air Leakage Reduction Baseline Rim Joist Bay Window 0.5% Air Leakage Reduction Case Study #1 Initial HERS Score 182 Initial 50 Pa After sealing rim joist 182 ACH after sealing rim joist HERS Score not impacted
41 4 Basement window frames (perimeter) ¼ can Pro Window & Door with gun applicator and 15 minutes
42 Basement Windows Air Leakage (cfm) at 50Pa Baseline Air Leakage Reduction Rim Joist Bay Window Basement Windows What was done: Perimeter sealed Product used: ¼ can Pro Window & Door with gun applicator Labor: 15 minutes 3000 Case Study #1
43 Basement Windows Air Leakage (cfm) at 50Pa Baseline Air Leakage Reduction Rim Joist Bay Window Basement Windows What was done: Perimeter sealed Product used: ¼ can Pro Window & Door with gun applicator Labor: 15 minutes 3000 Case Study #1 Initial HERS Score 182 Initial 50 Pa After sealing rim joist 182 ACH after sealing rim joist 19.95
44 Basement Windows Air Leakage (cfm) at 50Pa Baseline Air Leakage Reduction Rim Joist Bay Window Basement Windows 0.4% Air Leakage Reduction What was done: Perimeter sealed Product used: ¼ can Pro Window & Door with gun applicator Labor: 15 minutes 3000 Case Study #1 Initial HERS Score 182 Initial 50 Pa After sealing rim joist 182 ACH after sealing rim joist HERS Score not impacted
45 12 exterior stud cavities in attic 2.5 can Pro G&C with gun applicator and 2.1 hours labor
46 Attic Stud Cavities Air Leakage Reduction 6000 What was done: 12 cavities sealed Product used: 2.5 cans Pro G&C with gun applicator Labor: 2.1 hours Air Leakage (cfm) at 50 Pa Baseline Rim Joist Bay WindowBasement Windows Stud Cavities 3000 Case Study #1
47 Attic Stud Cavities Air Leakage Reduction 6000 What was done: 12 cavities sealed Product used: 2.5 cans Pro G&C with gun applicator Labor: 2.1 hours Air Leakage (cfm) at 50 Pa Baseline Rim Joist Bay WindowBasement Windows Stud Cavities 3000 Case Study #1 Initial HERS Score 182 Initial 50 Pa After sealing rim joist 180 ACH after sealing rim joist 18.92
48 Attic Stud Cavities What was done: 12 cavities sealed Product used: 2.5 cans Pro G&C with gun applicator Labor: 2.1 hours Air Leakage (cfm) at 50 Pa Baseline Air Leakage Reduction Rim Joist 5% Air Leakage Reduction Bay WindowBasement Windows Stud Cavities 3000 Case Study #1 Initial HERS Score 182 Initial 50 Pa After sealing rim joist 180 ACH after sealing rim joist HERS Score reduced 2 points
49 Case Study #2 Built in 1963
50 Open masonry block
51 Installed cut-to-fit XPS foam over holes
52 2 cans Pro G&C with gun applicator and ¾ hour Sealed with Pro G&C 80 linear feet of rim joist sealed
53 R-13 fiberglass batts added 26 fiberglass batts and ½ hour 36 linear feet of rim joist
54 Rim Joist Air Leakage Reduction linear feet of rim joist Air Leakage (cfm ) at 50 Pa Baseline Rim Joist Product used: 2 cans Pro G&C with gun applicator Labor: 0.75 hours 3000 Case Study #2
55 Rim Joist Air Leakage Reduction linear feet of rim joist Air Leakage (cfm ) at 50 Pa Baseline Rim Joist Product used: 2 cans Pro G&C with gun applicator Labor: 0.75 hours 3000 Case Study #2 Initial HERS Score 108 Initial 50 Pa After sealing rim joist 102 ACH after sealing rim joist 11.33
56 Rim Joist 4500 Air Leakage Reduction 8% Air Leakage Reduction 80 linear feet of rim joist Air Leakage (cfm ) at 50 Pa Baseline Rim Joist Product used: 2 cans Pro G&C with gun applicator Labor: 0.75 hours 3000 Case Study #2 Initial HERS Score 108 Initial 50 Pa After sealing rim joist 102 ACH after sealing rim joist HERS Score reduced 6 points!
57 Case #3 Built in 1961
58 Batt insulation was removed and replaced after sealing
59 Rim Joist Air Leakage (cfm ) at 50 Pa Air Leakage Reduction Baseline Rim Joist 149 linear feet of rim joist Product used: 9 cans Consumer G&C Labor: 3 hours (DIY) Case Study #3
60 Rim Joist Air Leakage (cfm ) at 50 Pa Air Leakage Reduction Baseline Rim Joist 149 linear feet of rim joist Product used: 9 cans Consumer G&C Labor: 3 hours (DIY) Case Study #3 Initial HERS Score 88 Initial 50 Pa 6.44 After sealing rim joist 85 ACH after sealing rim joist 5.82
61 Air Leakage (cfm ) at 50 Pa Rim Joist Air Leakage Reduction Baseline Rim Joist 10% Air Leakage Reduction 149 linear feet of rim joist Product used: 9 cans Consumer G&C Labor: 3 hours (DIY) Case Study #3 Initial HERS Score 88 Initial 50 Pa 6.44 After sealing rim joist 85 ACH after sealing rim joist 5.82 HERS Score reduced 3 points to 85!
62 Case #4 Built in 1975
63 Fiberglass batts removed, R-6 in band
64 Two component foam installed as air seal and insulation
65 Increased to R-16
66 Rim Joist Air Leakage Reduction Air Leakage (cfm ) at 50 Pa Baseline Rim Joist 214 linear feet of rim joist Product used: 3 kits of Two Component Foam Labor: 2 hours Case Study #4
67 Rim Joist Air Leakage Reduction Air Leakage (cfm ) at 50 Pa Baseline Rim Joist 214 linear feet of rim joist Product used: 3 kits of Two Component Foam Labor: 2 hours Case Study #4 Initial HERS score 88 Initial ACH at 50 Pa 5.16 After sealing rim joist 87 ACH after sealing rim joist 4.52
68 Rim Joist Air Leakage (cfm ) at 50 Pa Air Leakage Reduction Baseline Case Study #4 Rim Joist 13% Air Leakage Reduction 214 linear feet of rim joist Product used: 3 kits of Two Component Foam Labor: 2 hours Would have been 90 with no insulation in band Initial HERS score 88 Initial ACH at 50 Pa 5.16 After sealing rim joist 87 ACH after sealing rim joist 4.52 HERS score reduced 1 point
69 Assumptions and Calculations Energy savings est using REM/Rate Conversion: (MMBtu/yr)( )=kWh/yr no accounting for furnace efficiency difference ROI = (savings / investment) * 100 Payback = product cost / whole house H&C savings
70 Payback Analysis of Sealing Rim Joist Product Avg Payback Time (months) Avg Energy Saved Per House (Kwh/yr) Avg Energy Cost Savings Per House ($/yr) Avg # of Cans/Application Avg One Yr Return on Investment (%) One compoconsumer G&C (12 oz) 160 One component Pro G&C (20 oz) 600 * Calculated based on 15 case studies of homes
71 Selected Case Study Payback Avg Energy Saved Per House (Kwh/yr) Avg Energy Cost Savings Per House ($/yr) Avg One Yr Return on Investment (%) House Avg Payback Time (months) Avg # of Cans/Application Case Study # (20 oz) 749 Case Study # (20 oz) 902 Case Study # (12 oz) 79 Case Study # (180 kits) 4 * Calculated based on 15 case studies of homes
72 Plumbing Penetrations
73 Plumbing Penetrations 2 plumbing penetrations Product used: ½ can Consumer G&C Labor: 10 minutes Air Leakage (cfm ) at 50 Pa Air Leakage Reduction Baseline Plumbing Plumbing Penetrations
74 Plumbing Penetrations Air Leakage Reduction 2 plumbing penetrations Product used: ½ can Consumer G&C Labor: 10 minutes Air Leakage (cfm ) at 50 Pa Baseline Plumbing Penetrations Plumbing Initial HERS score 78 Initial ACH at 50 Pa 2.12 After sealing penetrations 78 ACH after sealing 1.95
75 2 plumbing penetrations Product used: ½ can Consumer G&C Labor: 10 minutes Plumbing Penetrations Air Leakage (cfm ) at 50 Pa Air Leakage Reduction Baseline Plumbing Penetrations Plumbing 8% Air Leakage Reduction Initial HERS score 78 Initial ACH at 50 Pa 2.12 After sealing penetrations 78 ACH after sealing 1.95 HERS score did not change
76 Windows
77 Basement Windows Air Leakage Reduction Air Leakag e (cfm ) at 50 Pa Baseline Windows 2 basement windows Product used: 1.25 cans Consumer W&D Labor: 15minutes 1000 Windows
78 Basement Windows Air Leakage Reduction Air Leakag e (cfm ) at 50 Pa Baseline Windows 2 basement windows Product used: 1.25 cans Consumer W&D Labor: 15minutes 1000 Windows Initial HERS score 78 Initial ACH at 50 Pa 1.95 After sealing windows 78 ACH after sealing 1.84
79 Basement Windows Air Leakag e (cfm ) at 50 Pa Air Leakage Reduction Baseline Windows 5% Air Leakage Reduction 2 basement windows Product used: 1.25 cans Consumer W&D Labor: 15minutes 1000 Windows Initial HERS score 78 Initial ACH at 50 Pa 1.95 After sealing windows 78 ACH after sealing 1.84 HERS score did not change
80 Electrical Outlets Sealed 11/21 outlets Air Leakage (cfm) at 50 Pa Air Leakage Reduction Electrical Outlets No Reduction!
81 Payback Analysis Avg Payback Time (months) Avg Energy Saved Per House (Kwh/yr) Avg Energy Cost Savings Per House ($/yr) Avg One Yr Return on Investment (%) Avg # of Application Product Cans/Application Plumbing Penetrations Consumer G&C (12 oz) 2370 Cantilever bays/walls Pro G&C (20 oz) 230 Exposed stud cavities(attics) Pro G&C (20 oz) 240 Sealing can lights to drywall Consumer W&D (12 oz) 480 Two windows Consumer W&D (12 oz) 430 Results based on 15 case studies of homes built
82 Payback Analysis Summary Installation: avg 2 hours 1 yr ROI: 145 2,370%, avg 630% 7 yr ROI: avg 4,390% Payback: avg 4 months
83 Payback: 6 months* ROI at 7 years 1,400% Payback = CFL cost/annual electricity savings, estimated CFL Lifetime is claimed to be 7 years
84 Air Sealing Fast Cost effective High ROI (~ 2.5x 7 yrs) Short payback Can reduce HERS score
85 Acknowledgements Doug Bibee, Dow Chemical Company Don Nelson, DR Nelson & Associates
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