THE 3-LITER-HOUSE AN INNOVATION IN THE MODERNIZATION OF OLD PROPERTIES Albrecht Göhring Diplom-Ingenieur EnergieEffizienzAgentur Rhein-Neckar-Dreieck ggmbh Ludwigshafen/Rhein, Germany [1] 1. BASF modernizes the Brunck Quarter BASF s housing company, LUWOGE/GEWOGE Wohnungsunternehmen der BASF GmbH, is going to great expense to refurbish the 70-year-old Brunck quarter in the Friesenheim district of Ludwigshafen, investing about EUR 50 million in the project. The company has set itself the target of bringing this residential area, which is right in front of the gates to the BASF works, up to modern standards with regard to comfort and energy consumption. The aim is to make the homes and their surroundings attractive again for young families with children, shift workers and elderly people. This is to be achieved with a sustainable urban development plan involving a combination of conservation and modernization of existing properties together with demolition and the building of new properties. When the refurbishment is complete, about 500 of the 850 apartments will remain. Because many of the old apartments are much too small, the total floor area will, however, remain about the same. 2. Attractive surroundings and a lot of greenery The urban development measures are however not limited to improving the quality of housing. LUWOGE is also laying out new green areas; existing green spaces are being redesigned and the inner courts upgraded with small playgrounds and quiet areas. In conjunction with the Ludwigshafen municipal authority, LUWOGE has devised a traffic plan with traffic-calmed areas. Thus, the quality of the Brunck quarter as a residential area will be improved in as sustainable and exemplary way. [1 published by approval of LUWOGE BASF Group]
As a result of attractive new buildings along Brunckstraße, this Avenue will become a more pleasant gateway to BASF and the town of Ludwigshafen. 3. Modern architecture in den Brunck quarter In addition to the modernization work, new building is also underway in the Brunck quarter. Where the fabric of buildings was such that refurbishment was not possible at reasonable cost, properties have been pulled down. Three projects for new buildings have been carried out. A modern block with 36 apartments which are specifically geared to the needs of senior citizens and shift workers is being built on Brunckstraße, between Sternstraße and Ruthenstraße. Tenants will be moving in at the end of 2001. The Service Center, which is also situated on Brunckstraße and will accommodate LUWOGE and the BASF company health insurance fund, will be the showpiece of the Brunck quarter. Modern row houses which are designed to meet the needs of young families with children are under construction directly behind the Service Center. 4. A good atmosphere in the Brunck quarter Having been packed with composite thermal insulation systems, the modernized buildings in the Brunck quarter have an annual heating requirement of 70 kwh/m², which equates to 7 liters of heating oil per square meter. As a result, all the modernized old properties meet the thermal insulation requirements of German Energy Saving Ordinance 2000 (Energiesparverordnung 2000), even though it is common knowledge that these regulations are only binding in relation to new buildings. Together with the changeover to natural gas and the use of modern heating systems, the emissions of carbon dioxide (CO 2 ) from the entire residential area being cut by 80 percent. 5. Pointing the way ahead for property modernization Very early on, the responsible people in LUWOGE developed the idea of using a building to demonstrate what was technically achievable and sensible within the context of an overall plan for the Brunck quarter in conjunction with BASF and partner organizations, to cut the annual heating requirement in old properties to 30 kwh/m², using a plan comprising optimum thermal insulation, efficient energy production and innovative building technology. That equates to a consumption of 3 liters of heating oil per square meter of floor area and a sevenfold saving compared with an unrefurbished old property. The vision led to Prototype I, which later developed into the House of the Future and now, as the first 3-liter-house resulting from the refurbishment of an old building, offers comfortable and environmentally compatible accommodation to eight tenants and their families. 6. New prospects for old properties Almost 95 percent of the total consumption of heating energy is accounted for by old residential properties. At least 24 of the 34 million apartments in old properties in Germany are in need of refurbishment. These figures show not only where the potential is, but also where the greatest challenge is, for bringing about noticeable cuts in energy consumption and significant reductions in CO 2 emissions in the future through extensive thermal insulation and advanced heating technology. The refurbishment of old properties is environmental protection
in practice. LUWOGE s 3-Liter-House opens up completely new prospects in this market. It must not be forgotten that energy prices are continuing to rise. The equation environmental protection = increasing marketability applies to housing companies. By investing in measures which reduce the consumption of energy in old properties significantly, housing companies can secure a competitive advantage for themselves. Lower incidental costs (heating, lighting and services), together with an increase in comfort, are top priority for tenants. 7. The know-how Verbund makes the 3-Liter House possible LUWOGE s 3-Liter House is a good example of how an optimum system solution can be achieved through the combining of different core competencies and the sharing of expertise in a so-called know-how Verbund not forgetting the financial aspects. Together with manufacturers from the building industry, building services companies and BASF, a plan was developed, under the leadership of LUWOGE, to use innovative components to create a building which was highly efficient with regard to energy use and in other aspects. A threeyear scientific measurement program, collecting a large quantity of data in Prototype I, provides valuable information for the development of property refurbishment as a market of the future. 8. Optimum thermal insulation in the 3-Liter House In order to achieve an annual energy consumption equivalent to 3 liters of oil per square meter of floor area, a great deal of insulation work is required, especially in an old property where the fabric and construction fall far short of the present-day state of the art. For this reason, the following rule in particular should be observed with regard to the refurbishment of old properties: cellars, walls, windows and roofs must not be viewed as individual, isolated solutions; instead, an all-encompassing energy plan is the key to success. Only in this way can a windproof and airtight envelope be achieved and thermal bridges avoided. Neopor, a recently developed type of expanded polystyrene, played an important role in meeting these requirements in the refurbishment of the 3-Liter House. 9. Neopor opens up new dimensions in external wall insulation The difference between Neopor and the familiar Styropor as an insulating material is apparent immediately. Neopor boards are not white, but silvery-gray. The new material is based on polystyrene and contains microscopically small flakes of graphite which reflect heat and make the boards virtually impermeable to thermal radiation. As a result, Neopor has a considerably higher thermal insulation capacity than conventional insulating materials. A board of Neopor can be up to 20 percent thinner than a conventional board of Styropor with the same density (i.e. with the same insolating performance). Specifically in relations to the refurbishment of old properties, where it has not been possible to fit thick insulation packages in the past for constructional reasons, this is an aspect which opens up new prospects for the installation of composite thermal insulation systems. The new insulating material is also attractive for ecological and economic reasons. Because less raw materials is needed for the same insulating performance, there are savings in costs and resources. Every board fitted on external walls eases the pressure on the environment. About ten liters of crude oil are needed to produce 2 square meters of Neopor (10 cm thick).
But this same board will save approximately 1,200 liters of heating oil over a period of 50 years! 10. Windows help to cut energy consumption The windows are an important element in the energy plan of the 3-Liter-House. Increasing the window area makes passive use of solar energy possible and also improves the natural lighting in the living areas. BASF s triple-glazed Vinidur plastic-framed windows, filled with inert gas, provide thermal insulation; the U value is about 0.8 W/m²K. 11. The 3-Liter House is full of innovations The modernization of energy use in the 3-Liter House does not end with the optimized thermal insulation of the fabric of the building; it continues in the inherent qualities of the property. One cannot see, just by looking at the building, what technical refinements and innovative products have been incorporated in it. The only thing which counts is the benefit to the occupants and the environment, not any attempt to impress. 12. The air is always clean and healthy A controllable ventilation system in the 3-Liter House ensures that all rooms get optimum ventilation at all times. At the same time, 85 percent of the heat produced is recovered. 13. The air-conditioning system in the wall It is virtually inconceivable that a room can be warm in the winter and cool in the summer without a complicated an expensive air-conditioning system. But these conditions are possible in two rooms in the 3-Liter House. An interior plaster designed to retain latent heat ensures that the indoor climate there is always comfortable and pleasant. This interior plaster was developed by BASF. Between 10 and 25 percent of it is made up of a material in the form of wax particles which stores latent heat. This means between 750 an d1500 grams of wax per square meter of wall. The heat absorption capacity of two centimetres of this plaster is equivalent to that of a 20 cm thick timber-bricked wall. If it gets too hot outside, the wax melts and thereby uses up retained heat; as a result, it stays cool longer inside. In order that the wax can be incorporated into paints or plaster, BASF researchers have packed it in microcapsules. 14. The fuel cell as a miniature power-plant in the cellar The 3-Liter House is supplied by means of a fuel cell which is designed to provide some of the overall heating energy requirement of the building. Additional supplies come from a modern heating boiler and the public power supply network. The fuel cell is an important factor in the energy plan of the 3-Liter House. As a result of improvements in insulation due to constructional features, new and innovative supply solutions are increasingly coming to the fore to meet the energy requirements for spatial heating and hot non-potable water in a more energy-efficient way. Fuel cell technology will play a key role here owing to its high efficiency and lower emissions. The miniature power-plant in Ludwigshafen is based on the principle of the polymer membrane fuel cell. In this type of cell, natural gas is first converted into a hydrogen-rich process gas in the fuel gas reformer and then fed into the fuel cell stack. There, the fuel cell process takes place as air is fed in. The residual gases are burnt up completely in a catalytic
afterburner and the emissions are considerably lower than those from a conventional heating system. Because it is one of the first systems of this kind in Germany, it is being tested over three years in the context of a scientific study and for this reason measuring equipment has been installed in the building. 15. Company housing policy a welfare benefit with a history LUWOGE and GEWOGE are BASF s two housing companies and they are now responsible for a stock of 10,000 rented apartments. Now that there has been a very sharp decline in the amount of new building work over the past few years, the maintenance and modernization of the existing housing stock are becoming increasingly important. An up-to-date standard of housing, attractive ground plans, harmonious surroundings, social compatibility and tenant satisfaction constitute a unity here. Since 1995 the housing companies have been active in large-scale urban regeneration projects. The improvement and revitalization of downtown residential areas has become a joint task with the local authority and the state, with housing programs and town-planning measures being combined into cooperative housing projects by committed partners. The Water Tower Estate project in Schwarzheide and the Brunck quarter project in Ludwigshafen are models which can also be applied far beyond the boundaries of Ludwigshafen. 16. BASF a leading chemical company BASF is a transnational chemical company that aims to increase and sustain its corporate value through growth and innovation. The company s product range includes high-value chemicals, plastics, colorants and pigments, dispersions, automotive and industrial coatings, agricultural products and fine chemicals as well as crude oil and natural gas. BASF s approach to integration, known in German as Verbund, is one of its particular strengths, ensuring cost leadership and a unique competitive advantage. BASF is one of the world s leading chemical companies. BASF acts in accordance with the principles of Sustainable Development. On the internet BASF can be found at www.basf.com. For the construction industry BASF produces basic materials such as dispersions or expandable polystyrene for the manufacture of insulating materials. The most recent addition to this family of products is Neopor. Neopor is an expandable polystyrene for the manufacture of gray foams. 17. Summary 3-Liter House in Ludwigshafen/Rhein: Only three liters of heating oil per square meter per annum and an 80 percent reduction in CO 2 emissions at the same time is that possible? It is in BASF s Three-Liter-House in Ludwigshafen. This ultramodern building, which also known as the House of the Future, is a totally refurbished old property with nine dwelling units covering a total of 700 square meters. Compared with an unrefurbished old building, the annual heating requirement is between seven and ten times lower. Expressed in terms of money, this means that the annual heating costs for a tenant in a 100 m² apartment are cut from 700 Euro to less than 100 Euro and energy consumption is reduced by 80 percent. BASF is investing about 1,5 million Euro in the project. The energy savings and the associated reduction in CO 2 emissions are achieved first and foremost by way of special thermal insulation. Neopor is a type of expanded polystyrene,
recently developed by BASF, which is particularly suitable for thermal insulation on outside walls. Over a period of 50 years 1200 liters of heating oil can be saved with ten liters of crude oil which are needed to produce a slab of Neopor. Neopor has another advantage over conventional insulation materials: infrared absorbers and reflectors also reduce its thermal conductivity. Warm in the winter and cool in the summer: BASF has developed a new kind of interior render, containing a material which stores latent heat. Between 10 and 25 percent of the render is made up of this material, so this means 750 to 1500 grams of wax per square meter. The heat absorption capacity of two centimetres of this render is equivalent to that of a 20 cm thick timber-bricked wall. The heat-retaining material provides a pleasant and comfortable indoor climate. If, for example, it gets too hot outside, the wax uses up heat as it melts, and there is no increase in the room temperature. The wax max be solid or liquid, depending on the time of the year. In order that it can be incorporated into concrete or plaster, BASF researchers have packed it in microcapsules. The windows in the 3-Liter House are triple glazed and have a U value of just 0.8 W/m²K. The space between the panes is filled with inert gas for even greater energy saving. The frames, which are made from BASF s Vinidur upvc, feature a urethane foam core for optimal insulation. The 3-Liter House is heated, amongst other things, by a fuel cell which uses natural gas as its source of energy. It is one of the first systems of this kind in Germany which are being used under real conditions and tested in the context of a scientific study with external partners. For this reason the building is equipped with the latest measuring instruments which record, store and show all the consumption data locally in a digital form. The scientists evaluate a total of 120 million items of measurement data annually. The quantities of atmospheric pollutants arising from the use of this highly efficient energy converter are very low because the main reaction product is water. For more information regarding the 3-Liter House especially for more technical details don t hesitate to contact either Dipl.-Ing. Albrecht Göhring, Managing Director of the EnergyEffencyAgency Rhein-Neckar-Dreieck ggmbh, Phone 0049-621-60-47247, e-mail: info@e2a.de or Dipl.-Ing. Wolfgang Greifenhagen, Managing Director of LUWOGE BASF Group, Phone 0049-621-60-41011, e-mail: wolgang.greifenhagen@basf-ag.de.
17. Photographs 1. View of the Brunck quarter with the site 2. Arial photo of the Brunck quarter. of the 3-Liter House (blue). 3. The 3-Liter House under contruction. 4. German Chancellor, Gerhard Schröder, Prof. Dr. Jürgen Strube, Chairman of Supervisory Board BASF AG and Kurt Beck, Minister- President of Rhineland-Palatinate.
5. Cross section of the 3-Liter House. 6. Benefits of energy saving.
7., 8.,9.: The entire shell of the 3-Liter House is encased in thermal insulation. 10. Detail of the roof. 11. Detail of the window. 12. Heat recovery. 13. Fuel cell.
14.,15.: Views of the 3-Liter House after refurbishment.