Scott Cummings Dow Building Solutions Adam Weesner MSKTD & Associates Linda Jeng Dow Building Solutions

Transcription

1 Continuous Residential Air Barriers/Thermal Boundaries Scott Cummings Dow Building Solutions Adam Weesner MSKTD & Associates Linda Jeng Dow Building Solutions Introduction Industrial Evolution Evolving Codes Backed by Building Science - R&D Update Residential Net Zero Examples project:infill Case Study Economics Summary Future 1

2 3 As much as I love our industry, it s archaic. We build from familiarity; instead, we should be promoting environmental stewardship. Marc Rutenberg, Builder Developer 4 Walls: Significant Loss 5% through ceilings 14% through windows 38% through air infiltration 3% through doors 17% through frame walls 1% through basement floors 22% through basement walls 2

3 5 Thermal Shorts Wood: R1/ inch Batts: R3.5/inch Discontinuous Air Barrier and Thermal Envelope 6 Fenestrations Air/Moisture Barrier Thermal Barrier Shell Foundation 3

4 7 + + =??? Energy Loss & Condensation 8 28 F OSB Sheathing Warm 68 F Cold 25 F Thermal Barrier Air and Moisture Barrier R-15.5 R-1 8 4

5 9 D r y w a l l Fiberglass O S B C l a d d i n g 9 10 R-0.45 XPS or SIS Insulating Sheathing R-0.5 R-5 R-15 Warm 68 F Cold 25 F R-15.5 R

6 11 Insulating Sheathing 37 F! Warm 68 F Cold 25 F R-15.5 R D r y w a l l Fiberglass I n s u l a t e d S h e a t h i n g C l a d d i n g 12 6

7 13 Air Barrier + Moisture Thermal Barrier + Barrier =??? Optimum Thermal and Moisture Protection 14 Moisture Content of HW/OSB vs. R 3 and R 5.5 Structural Insulated Sheathing Chicago, IL WUFI Simulation 14 7

8 15 Traditional Foam Sheathed Walls Foam Sheathed Walls and Roof Deck Roof Wall Juncture 16 Traditional Foam Sheathed Walls Foam Sheathed Walls and Foundation Wall/Below Grade Juncture 8

9 17 CI SPF or FG 1 or 2 Comp. Foam Sealant XPS Air Sealing Fenestrations ti Roof Pressure Boundary Thermal Air and Moisture Barrier in One Shell Foundation Zone 3 Wall 2012 Zone 3 Wall R-13 Batts R-13 Batts + R5 ci and 3ACH50 9

10 2/29/ Courtesy of Building Science Corp. 20 Courtesy of Building Science Corp. 10

11 21 Courtesy of Building Science Corp. 22 IECC Code Version Zone Wall Ceiling Slab Basement Crawlspace @ 2 Ft. 10/13 10/ / @ 2 Ft. 10/13 10/ / @ 4 Ft. 10/13 10/ @ 2 Ft. 10/13 10/ / @ 2 Ft. 10/13 10/ / @ 4 Ft. 10/13 10/ / @ 2 Ft. 5/13 5/ / @ 2 Ft. 10/13 10/ / @ 2 Ft. 15/19 15/ / @ 4 Ft. 15/19 15/19 11

12 23 3 ACH50 Zones 3 to 8 And ci R5+ 5 ACH50 Zones 1, 2 24 Midland, MI Midland MI Climate (Average Weather) Data Statistic Units Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Average Min T F Max T F Heating Degree Days Cooling Degree Days Monthly inches Precipitation 12

13 25 Hut Mission Provide comparative long-term wall systems performance data Promote system best practices Identify development opportunities from performance gaps Design & Construction Advanced Humidity and temperature control: Air-to-air heat pump plus humidification; Ceiling distribution for flexibility Collaboration led by Gary Parsons, Dow Scientist and John Straube, Building Science Corp. Energy efficient construction: ICF foundation 2 STYROFOAMTM below slab Spray foam critical seal at roof edge 31 test zones possible with 4 to 12 wall sections $1MM investment for long term assembly study - $625/sqft Unique Features Amongst the most advanced and largest field test structure in N.A. 10 wall specimen height enables floor sections to be included Corner sections are test sections State of the Science design and installation details Installation and design both have to support clear zone separation in the wall sections in the same plane Air sealing is important for performance and data zone section integrity 13

14 27 Vinyl and Cultured Stone over WRB (Water resistive barrier) What is the relative moisture and thermal performance of residential wall assemblies, which include popular cladding materials? Compare Code Wall with building paper to Improved Wall with WEATHERMATE TM Plus and Best Wall STYROFOAM TM. From exterior: 1: Dow Wall 2x4 R5+R13 1 STYROFOAM TM with taped seams, R13 Batt cavity, and R8 FROTH PAK in rim joist 2: Improved Wall 2x4 R13 Oriented strand board with WEATHERMATE TM PLUS, R13 batt cavity, R21 faced batt rim joist 3: Code Wall 2x4 R13 Oriented strand board with building paper, R13 batt cavity R21 faced batt rim joist 28 Steel Stud Wall Assemblies (on concrete slab) What is the advantage of continuous insulation compared with conventional cavity insulation construction? View from interior: 1: Base Wall R19 Cavity DensGlass TM with batt insulation 2: R10 ci + R9.1 Cavity 1.55 THERMAX with 1.5 of spray foam insulation 3: R19 ci + R9.1 Cavity 3 THERMAX with 1.5 of spray foam insulation 14

15 29 12 home energy efficient test community in Midland, MI with partner builder Nation s first subdivision designed to generate scientific, whole home performance data starting Expected HERS Fully instrumented with to monitor real whole home data 60 sensors/home! Plan Name: BASELINE 2012 Performance: Minimum 2012 Performance: Premium Beyond Code: Premium Package Cost Package featuring all Dow Meet 2012 IECC or equivalent for Exceed 2012 IECC or equivalent for Meet 2006 IECC or equivalent for Meet 2012 IECC or equivalent for typical Zone 5/6 construction with typical Zone 5/6 construction with many Plan Concept: typical Zone 5/6 construction at the typical Zone 5/6 construction at the some "best practices" of building "best practices" of building science to lowest possible price point lowest possible price point science to enhance performance enhance performance (typical Cobblestone home) (InVision home without renewables) Beyond 2012 Energy Code Compliance: 2006 Prescriptive 2012 Performance 2012 Performance Performance Estimated/Target HERS mid 40s RIM & BAND JOIST INTERIOR Fiberglass batt, kraft-faced, friction Fiberglass batt, kraft-faced, friction Insulating Material Dow SPF Dow SPF fit fit Thickness of Insulating Material 6", R-19 6", R ", R ", R-16 Total R-Value of Insulation between floor joists EXTERIOR Insulating Material None None STYROFOAM XPS (UFIT T&G) STYROFOAM XPS (UFIT T&G) Thickness of Insulating Material n/a n/a 1 2 Total R-Value of Continuous n/a n/a 5 10 Insulation on exterior Total R-Value of Rim Joist Unfinished = R-10 continuous Unfinished = R-15 continuous Unfinished = R-15 continuous Unfinished = R-20 continuous Total R-Value of Basement Wall Finished = R-13 stud cavity Finished = R-19 stud cavity Finished = R-15 continuous Finished = R-20 continuous Total R-Value Under Slab Floor Thickness of Insulating Material n/a n/a 1", R-5.5 1" SIS, R " XPS, R-5 Total R-Value Above Grade Wall Marc Rutenberg Zero Energy America (ZEA): $1MM, Tampa, FL Vision Zero: $350, 000 home, Bay City, MI 3504 sqft, 1-story, 3 bedroom, above grade and full basement 286 CFM50 (0.56 ACH50), HERS Score -6 Est. Total Annual Energy Savings: $3, 507 InVision Zero: $250, 000 home, Midland, MI 1541sqft, 1-story 3 bedroom above grade with crawl space 395 CFM50 (0.22 ACH50), HERS 4 Est. Total Annual Energy Savings: $2, 441 project:infill: $202, 500* Habitat for Humanity, Fort Wayne, IN 1420 sqft, 1-story 4 bedroom above grade 400 CFM 50 (0.25 ACH50) [projected], HERS 46 Est. total Annual Energy Savings: $1,400 (without solar) *Construction Cost 15

16 31 Example Vision Zero 3504 sqft InVision Zero 1504 sqft project INfill 1420 sqft Wall Construction Vinyl/XPS or SIS/SPF Vinyl/XPS/SPF Cedar& Steel/XPS/SPF HERS Without Solar Actual Whole House Air Leakage (ACH/50Pa) Actual Whole House Air Leakage (cfm/50pa) Energy Savings* without Solar Midland, MI $2,617 $1,636 $1,466 estimate Energy Savings* with Solar $3,507 $2,441 $1,893 estimate Midland, MI Net Zero Energy Ready Homes with Energy Savings* without 75% 67% 78% Solar Midland, current MI thermal envelope and air sealing can Energy Savings* without Solar $2,649 $1,665 $1,394 estimate Fort Wayne, IN capture >65% of energy savings potential Energy Savings* with Solar Fort $3,561 $2,489 $1,806 estimate Wayne, IN Energy Savings* without without 74% installing 67% solar! 72% Solar Fort Wayne, IN Note*: Compared with 1970s existing house reference with R11 batt, and HERS

17 33 Zero Energy Effort Outside Ft. Wayne Takes Advantage of CI SPF (Cans, Kits, and Drums) Solar Intelligent Design Review Project Scope and Progress Project Architect 34 _site _orientation _natural air flow _sun/shade architect magazine 17

18 35 N First Floor Plan Mass Wall 36 The house requires active participation. It is meant to be operated; opened and closed depending on conditions. Active mechanical systems are ONLY secondary. 18

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20 XPS R20 1 & 2 Component Foam Sealants Window Shading 2 SPF R13 1 SPF R6.5 Low Pressure Foam Sealant CMU Mass Wall 2 XPS R10 1 XPS R5 9KBtu, 18 KBtu Mini Split Cooling 22KBtu, 11 KBtu Mini Split Heat 20

21 41 $202, 000 Estimated Construction Cost 1420 sq ft, 1-story 4 bedroom above grade (with loft) $103, 000 Estimated Donation Value $99,000 Estimated Out of Pocket Cost (includes estimated volunteer labor) A Second Approach to Energy Analysis 400 CFM 50 (0.25 ACH50) [projected], HERS 46 Est. total Annual Energy Savings (vs. existing 1970 reference): $1,394 (without solar) The house requires active participation. It is meant to be operated; opened and closed depending on conditions. Active mechanical systems are ONLY secondary. Est. total Annual Energy Savings: $1,394 (~72% of total with solar) with active systems 80%? 90%? 100%? 42 Project status: Framed and sheathed Continuous insulation: XPS R20 Wall = 4 thick 21

22 43 2 XPS R10 1 & 2 Component Foams 1 XPS R5 ci 5.5 FG R FG R13 Low Pressure Foam Sealant 1 XPS R5 44 Ft Wayne MMBTU/Yr $/Yr HERS Cost Savings Winter Summer Winter Summer $ $/Yr -Base Case $1851 $ Ft. Wayne -ZE Ready Upgrades $307 $ $20K $1394 Ft. Wayne IECC $587 $ $3962 $1416 Amortized Payback for 2012 IECC Wall 12 years ROI for ZE R20 ci/6.5 wall 2.7 years ROI for following 2012 IECC Net Savings (R5 ci /13 = $97+/Mo wall) Monthly Cost (4%/30) = $18.92 Monthly Savings = $

23 2/29/ Net Zero Energy ready building envelopes can capture most of the energy savings without solar Attention to detail at the transitions 2012 IECC type construction with ci captures fast ROI at modest cost Continuous Residential Air Barriers/Thermal Boundaries Best practice design and execution can Lower HERS Lower ACH50 No Projected Dewpoints Known Building Science Best Practices: Confirmed with Test Hut and Test Builds Demonstrated with Net Zero homes Meets continuous insulation and air leakage requirements in 2012 IECC 23

24 47 Insulating Sheathing 37 F! Warm 68 F Spray Foam R=20 Cold 25 F R-15.5 R D r y w a l l SPF I n s u l a t e d S h e a t h i n g C l a d d i n g 48 24

25 49 T out T in T wall Close to T in Result Alignment No Condensation Energy Performance Minor Cost Diff. RESNET - February 9, 2012 NOTICE: The data provided d in this slide presentation ti was collected up to 2012, and is given in good faith for informational purposes only. No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer's use and for ensuring that Customer's workplace and disposal practices are in compliance with applicable laws and other government enactments. The product shown in this literature may not be available for sale and/or available in all geographies where Dow is represented. The claims made may not have been approved for use in all countries. Dow assumes no obligation or liability for the information in this document. References to "Dow" or the "Company" mean the Dow legal entity selling the products to Customer unless otherwise expressly noted. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED. 25

26 Building Solutions Questions? Scott Cummings, Linda Jeng, Adam Weesner MSKTD & Associates,