MBCI Insulated Metal Panels
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1 MBCI Insulated Metal Panels White Paper What are Insulated Metal Panels? Insulated metal panels (IMPs) consist of two single-skin metal panels and a special foam insulation place between the two single-skin panels to provide superior R-values for greater thermal efficiency. R-values are used to describe the insulation properties; they are a measure of apparent thermal conductivity and describe the rate that heat energy is transferred through materials. More specifically, it is the measure of the ability to impede heat flow rather than to transmit heat. A higher R-value is better. Other thermal values measured in IMPs include K-factor and U-value. K-factor, or thermal conductivity, is the measure of a material s ability to transfer heat. A lower K-factor is better. U-value is a measure of how much heat is conducted through the material. A lower U-value is better. U is equal to 1/R. For example, a material with a U-value of 0.25 has an R- factor of 1, divided by 0.25, which is equal to an R-value of 4. Benefits of IMPs IMPs offer a number of product benefits for expanding the market. Because of their greater spanning and load bearing capabilities, IMPs are structurally strong, allowing for fewer secondary structural members. Buildings using IMPs can be closed in sooner, which results in shorter erection times. This reduces the labor costs and provides for earlier business starts. Insulated metal panels yield better insulating values while meeting ASHRAE (American Society of ing, Refrigerating, and Air-Conditioning Engineers) requirements without compromising structural schemes. ASHRAE code requirements mandate a 30 percent increase in thermal efficiency over the next three years. Using IMPs is the most cost-effective and efficient method of reaching these requirements. IMPs: Green Building and Energy Efficiency There are three major areas compelling the green movement: environmental, economical and societal. Insulated metal panels meet or exceed many of the standards for green certification and regulatory groups such as the United States Green Building Council s (USGBC) LEED program or the Green Building Initiative s (GBI) Green Globes for building envelopes. According to the U.S. Department of Energy (DOE), buildings demand a growing and significant amount of energy, 40 quadrillion Btu (quads) per year. Commercial buildings account for more than 40 percent of overall energy use. Commercial buildings are also responsible for more than 40 percent of all CO 2 emissions in the United States. Because of these two factors and the rising cost of operating commercial and industrial buildings, energy efficiency is also major driver in green building design and construction.
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3 IMPs provide ample green building and energy efficiency advantages: Due to the high R-value of IMPs, energy performance is optimized and consumption is reduced. This results in smaller quantities of greenhouse gases emitted into the atmosphere and reductions in energy costs. The use of IMPs in design maximizes the interior air quality when used with efficient heating and cooling systems. As with all metal roofs, there is minimal maintenance impact during its lifetime. The steel used on both the exterior and interior skins is comprised of recycled content and are also recyclable. IMPs have almost three times the R-value of traditional fiberglass insulation 7.14 per inch of panel thickness. There is no thermal drift associated with IMPs as experienced with rigid insulation. Insulated metal panels are sealed at the side laps and at all perimeter conditions. IMPs qualify as continuous insulation (ci) where required by IECC (International Energy Conservation Code ) and ASHRAE Continuous insulation is insulation that runs continuously over structural members and is free from significant thermal bridging. o IMPs eliminate the possibility of gaps in the insulation and thermal bridges. A thermal bridge is an assembly or component in the building envelope that transfers heat at a significantly higher rate than the surrounding insulated area. Thermal bridging is created by fasteners, joints and gaps. Thermal bridging can be a significant cause of heat loss and underperformance of insulation assemblies in commercial buildings. o Small gaps and compressed areas can reduce insulating levels significantly. A study of attic insulation performed by the South Carolina Energy Office found that just five percent voids in the insulation, typical in many installations, could reduce the overall R-value by more than 40 percent. MBCI roof panels are ASHRAE/California compliant Cool Roof colors as listed on the Cool Roof Rating Council (CRRC) Web site: o Cool metal roofing offers energy savings, helps reduce a building s cooling responsibilities and reduces the mitigation of urban heat islands (UHI). According to the U.S. Environmental Protection Agency, UHI consists of urban and suburban temperatures that are 2 F to 10 F warmer than nearby rural areas due to the inability to cool because of the modification of the land surface by urban development and waste heat generated by energy usage. LEED Advantages for Insulated Foam Panels LEED low-slope compliant colors for Credit SS 7.2 for Island Effect; LEED steep-slope compliant colors for Credit SS 7.2 for Island Effect; EA Prerequisite 2 (ASHRAE 90.1 Compliance); EA Credit 1, Optimize Energy Performance: o The building must be 14 percent more energy cost efficient than ASHRAE 90.1 Appendix G baseline building. Credit MR 4.1 and 4.2 for Recycled Content; Credit MR 5.1 and 5.2 for Regional Materials under v2.0 and 2.1. Incentives Federal tax credits are available for thermally efficient new construction meeting certain requirements.
4 The commercial building energy tax deduction may be available to the primary designer of federal, state and municipal buildings utilizing energy-efficient designs. Many state and local financing opportunities exist for energy efficient construction. In 2008, the Energy Policy Act of 2005 was extended to The policy rewards owners employing energy-efficient design in their buildings with a one-time tax deduction of $1.80 per square foot (/sf). The building must be 50 percent more efficient in energy cost over an ASHRAE compliant building. The act required energy modeling with EPA-approved software including: o DOE-2 o EnergyPlus o Other third-party software (see The tax deductions may be broken down into $.60/sf for each of the following: o Lighting o HVAC o Building Envelope A licensed engineer or architect must verify that installation is consistent with the design. Designers can take the tax credit for governmental projects that meet the criteria for energy efficiency as outlined in the act. (4) ALLOCATION OF DEDUCTION FOR PUBLIC PROPERTY. In the case of energy efficient commercial building property installed on or in property owned by a federal, state or local government or a political subdivision thereof, the Secretary shall promulgate a regulation to allow the allocation of the deduction to the person primarily responsible for designing the property in lieu of the owner of such property. Such person shall be treated as the taxpayer for purposes of this section. IMP Markets Because of the strong market for green building projects, insulated metal panels offer a wide array of potential customers. The American Institute of Architects reports that, although five years ago less than half of architects were incorporating green building practices, it is estimated that 90 percent of architects will incorporate sustainable elements by 2012 and 88 percent have received some training in green building. IMP markets include: Airplane Hangars Energy/Power Industry Food Industry Waste Water Treatment Facilities Manufacturing and Warehousing Mining Operations Public Work: Federal, state and local government work will be driven by green requirements. Schools and Universities Building Requirements and Climate Zones Different climate zones require different R-values for insulating buildings. CLIMATE ZONES 2006 IECC
5 R-5 thermal blocks are required on all metal buildings. Climate Zones 1, 7 and 8 require two layers of insulation (R-19 + R-10). R-10 insulation is draped perpendicularly to the purlins. R-19 insulation runs parallel to the purlins and is supported by the R-10 insulation. (See Table 502.2(2).)
6 IECC Building Requirements From the International Energy Conservation Code printed in 2006: TABLE 502.2(1) BUILDING ENVELOPE REQUIREMENTS OPAQUE ASSEMBLIES CLIMATE ZONE except Marine 5 and Marine Roofs Insulation entirely above deck R-15 ci R-15 ci R-15 ci R-15 ci R-20 ci R-20 ci R-25 ci R-25 ci Metal buildings (with R-5 and R-19 + thermal blocks a ) b R-10 R-19 R-19 R-19 R-19 R-19 R-19 + R-10 R-19 + R-10 Attic and other R-30 R-30 R-30 R-30 R-30 R-30 R-38 R-38, Above Grade Mass NR NR R-5.7 ci c,a R-5.7 ci c R-7.6 ci R-9.5 ci R-11.4 ci.3 ci Metal building b Metal framed R-3.8 ci R-3.8 ci Wood framed and other, Below Grade Below grade wall d NR NR NR NR NR NR Floors Mass NR R-5 ci R-5 ci R-10 ci R-10 ci R-10 ci R-15 ci R-15 ci Joist/Framing NR R-19 R-19 R-19 R-19 R-30 R-30 R-30 Slab-on-Grade Floors Unheated slabs NR NR NR NR NR NR NR R-10 for 24 in. ed slabs R-7.5 for 12 in. R-7.5 for 12 in. R-7.5 for 12 in. R-7.5 for 12 in. R-7.5 for 24 in. R-10 for 36 in. R-10 for 36 in. R-10 for 48 in. Opaque Doors Swinging U 0.70 U 0.70 U 0.70 U 0.70 U 0.70 U 0.70 U 0.70 U 0.50 Roll-up or sliding U 1.45 U 1.45 U 1.45 U 1.45 U 1.45 U 0.50 U 0.50 U 0.50 For SI: 1 inch = 25.4 mm ci: Continuous Insulation NR: No Requirement a. Thermal blocks are a minimum R-5 of rigid insulation, which extends 1 inch beyond the width of the purlin on each side, perpendicular to the purlin. b. Assembly descriptions can be found in Table 502.2(2). c. R-5.7 ci may be substituted with concrete block walls complying with ASTMC 90, ungrounded or partially grounded at 32 in. or less on center vertically and 48 in. or less on center horizontally, with ungrounded cones filled with material having a maximum thermal conductivity of 0.44 Btu-in/h * ft 2 * F. d. Insulation is not required for mass walls in Climate Zones 3A located the Warm-Humid line, and in Zone 3B.
7 TABLE 502.2(2) METAL BUILDING ASSEMBLY DESCRIPTIONS ROOFS DESCRIPTIONS REFERENCE R-19 + R-10 Filled cavity roof. ASHRAE/IESNA 90.1 Table A2.3 Thermal blocks are a minimum R-5 of rigid insulation, which extends 1 in. beyond the width of the purlin on each side, perpendicular to the purlin. This construction is R-10 insulation batts draped perpendicularly over the purlins with enough looseness to allow R-19 batt to be laid above it, parallel to the purlins. Thermal blocks are then placed above the purlin/batt, and the roof deck is secured to the purlins. In the metal building industry, this is known as the sag and bag insulation system. R-19 Standing seam with single insulation layer. Thermal blocks are a minimum R-5 of rigid insulation, which extends 1 in. beyond the width of the purlin on each side, perpendicular to the purlin. This construction R-19 insulation batts draped perpendicularly over the purlins. Thermal blocks are then placed above the purlin/batt, and the roof deck is secured to the purlins. WALLS Single seam with single insulation layer. The first layer of insulation batts is installed continuously perpendicular to the girts and is compressed as the metal skin is attached to the girts. Double insulation layer. The first layer of insulation batts is installed continuously perpendicular to the girts and is compressed as the metal skin is attached to the girts. The second layer of insulation batts is installed within the framing cavity. ASHRAE/IESNA 90.1 Table A2.3 ASHRAE/IESNA 90.1 Table A3.2 ASHRAE/IESNA 90.1 Table A3.2 Climate Zones 1-4 except Marine require insulation installed perpendicular to the girts and compressed by the metal skin. Climate Zones Marine 4 and higher require insulation installed perpendicular and continuously to the girts. Additional insulation is installed within the framing cavity. All penetrations, openings, joints and seams in the building envelope must be sealed. Materials that can be used for this task include caulking, gasketing, tapes and moisture vapor-permeable wrapping material. ASHRAE 90.1 has similar requirements in Approved vapor retarder is required on all unvented framed cavities. Exceptions include Climate Zones 1-3, locations where moisture or freezing moisture will not damage the building materials or where other approved means to avoid condensation have been provided.
8 ASHRAE Building Requirements ASHRAE BUILDING ENVELOPE REQUIREMENTS CLIMATE ZONE Roofs except Cool Roofs Insulation entirely above deck R-15 ci R-20 ci R-20 ci R-20 ci R-20 ci R-20 ci R-20 ci R-20 ci Metal Building R-19 R-19 R-19 R-19 R-19 R-19 R-19 R- 19 Attic and Other R-30 R-38 R-38 R-38 R-38 R-38 R-38 R-49 Cool Roofs Insulation entirely above deck R-12 ci ci ci Metal Building R-16 NP NP NP NP NP Attic and Other R-24 R-25 R-25, Above Grade Mass NR R-5.7 ci R-7.6 ci R-9.5 ci R-11.4 ci.3 ci R-15.2 ci R-15.2 ci Metal Building Metal Framed R-3.8 ci Wood Framed and Other R-3.8 R-15.6 Using IMPs in Different Climate Zones Insulated metal panels have different effects in different climate zones. The parameters for the IMP Performance in Different Climate Zones study are as follows: 100 x 200 Commercial Warehouse 20 Eave Height, 1:12 roof slope (gable) o South Wall Storefront: 20-3x5 double pane windows, 4-6x7 single pane glass double doors o North Wall Loading Dock: 16-8x10 insulated steel doors o East and West 3-3x7 metal doors on each wall o Operating 7:00 a.m. to 6:00 p.m. Monday through Friday and 8:00 a.m. to 12:00 p.m. (noon) on Saturdays; 76 F cooling, 70 F heating o Closed Sundays and Holidays; 82 F cooling, 64 F heating Three climates investigated: Houston, Boston and Los Angeles o Two systems evaluated at each location Baseline: Galvalume SSR with 6 insulation on roof Light Stone metal walls with 4 insulation IMP: Houston and Los Angeles: 3 IMP Cool Roof (White) Boston: 3 IMP Burnished Slate colored roof 2 IMP walls with Light Stone color For all studies: o BTU (British Thermal Unit) is the amount of heat it takes to raise the temperature of a pound of water by one degree Fahrenheit. o (Mega BTU) is 1000 kbtus, or 1,000,000 BTUs. This is a measure of the rate of heat flow. o kbtu (Kilo BTU) is 1,000 BTUs per hour of time. This is a measure of the rate of heat flow. Commercial Warehouse - Houston, TX
9 Total External Building Envelope Cooling and ing Loads ing Loads MB Roof and MB Roof and Wall Conduction % % % % Roof Conduction % % % % Window Conduction % % % % Window Radiation % % % % Infiltration % % % % Total Savings % % Peak External Building Envelope Cooling and ing Loads ing Loads MB Roof and MB Roof and Wall Conduction % % % % Roof Conduction % % % % Window Conduction % % % % Window Radiation % % % % Infiltration % % % % Total Savings % % Utility s for ing and Cooling MB Roof and Energy Use Therms Therm Assumed Utility Cooling (Electricity) $5, $5,004 Rates Ventilation $1, $1,616 (Electricity) Electricity: $0.11 /kwh ing (Gas) 1408 $1, $1,393 Gas: $1.08 /CCF Total $9,033 $8,012 $1.05 /Therm Savings $1, % Study completed in January 2009.
10 Commercial Warehouse - Boston, MA Total External Building Envelope Cooling and ing Loads ing Loads MB Roof and MB Roof and Wall Conduction % % % % Roof Conduction % % % % Window Conduction % % % % Window Radiation % % % % Infiltration % % % % Total Savings % % Peak External Building Envelope Cooling and ing Loads ing Loads MB Roof and MB Roof and Wall Conduction % % % % Roof Conduction % % % % Window Conduction % % % % Window Radiation % % % % Infiltration % % % % Total Savings % % Utility s for ing and Cooling MB Roof and Energy Use Therms Therm Cooling (Electricity) $1, $1,643 Assumed Utility Rates Ventilation $2, $2,139 (Electricity) Electricity: $0.16 /kwh ing (Gas) 8340 $9, $8,107 Gas: $1.12 /CCF Total $13,045 $11,889 $1.08 /Therm Savings $1, % Study completed in January 2009.
11 Commercial Warehouse - Los Angeles, CA Total External Building Envelope Cooling and ing Loads ing Loads MB Roof and MB Roof and Wall Conduction % % % % Roof Conduction % % % % Window Conduction % % % % Window Radiation % % % % Infiltration % % % % Total Savings % % Peak External Building Envelope Cooling and ing Loads ing Loads MB Roof and MB Roof and Wall Conduction % % % % Roof Conduction % % % % Window Conduction % % % % Window Radiation % % % % Infiltration % % % % Total Savings % % Utility s for ing and Cooling MB Roof and Energy Use Therms Therm Cooling (Electricity) 6989 $ $622 Assumed Utility Rates Ventilation $2, $1,901 (Electricity) Electricity: $0.14 /kwh ing (Gas) $13, $12,664 Gas: $1.05 /CCF Total $16,425 $15,187 $1.02 /Therm Savings $1, % Study completed in January 2009.
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