Energy Code Compliance With SIPs. Frank Baker, PFB Corporation Don Ferrier, Ferrier Custom Homes

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1 Energy Code Compliance With SIPs Frank Baker, PFB Corporation Don Ferrier, Ferrier Custom Homes

2 Outline Overview of 2009 and 2012 energy codes Code compliance with SIPs Reducing air infiltration with SIP construction Side-by-side case studies Sealing methods Cost comparison from a builder s perspective Slide 2

3 Trending Towards Efficiency 2012 IECC 30% more efficient than 2006 IECC ENERGY STAR v3 in effect Jan 1, 2012 Advocates pushing for 70% 100% by 2030 DOE: affordable net zero energy homes by Challenge: carbon neutral by 2030 Slide 3

4 Slide 4

5 2009 IECC On average, 12% increase over 2006 Save homeowners $235/yr at current energy prices Slide 5

6 2009 IECC More efficient windows and doors Increased insulation Visual inspection of thermal envelope OR blower door test Duct leakage testing Thermal enclosure inspection No mechanical trade offs under performance path Slide 6

7 2009 IECC Air Infiltration 7 ACH50 all climate zones OR visual inspection Slide 7

8 Climate Zones Slide 8

9 2009 IECC Prescriptive requirements: insulation + windows CLIMATE ZONE FENESTRATIO N U-FACTOR SKYLIGHT U-FACTOR GLAZED FENESTRATION CEILING WOOD FRAME MASS WALL SHGC R-VALUE WALL R-VALUE R-VALUE 1 FLOOR R-VALUE BASEMENT WALL R- VALUE 2 SLAB R- VALUE & DEPTH / / CRAWL SPACE WALL R- VALUE /8 19 5/13 0 5/13 4 except Marine NR / /13 10, 2 ft 10/13 5 and Marine NR or / /13 10, 2 ft 10/ NR or / /19 10, 4 ft 10/13 7 and NR / /19 10, 4 ft 10/13 Slide 9

10 2012 IECC Even more efficient windows Even more insulation Blower door test REQUIRED Duct insulation Less duct leakage allowed Slide 10

11 2012 IECC Air infiltration 5 ACH50 in climate zones ACH50 in climate zones 3-8 AND visual inspection Slide 11

12 2012 IECC Prescriptive requirements: insulation + windows CLIMATE ZONE FENESTRATIO N U-FACTOR SKYLIGHT U-FACTOR GLAZED FENESTRATION CEILING WOOD FRAME MASS WALL SHGC R-VALUE WALL R-VALUE R-VALUE 1 FLOOR R-VALUE BASEMENT WALL R- VALUE 2 SLAB R- VALUE & DEPTH / / CRAWL SPACE WALL R- VALUE or /8 19 5/13 0 5/13 4 except Marine or / /13 10, 2 ft 10/13 5 and Marine NR or / /19 10, 2 ft 15/ NR or / /19 10, 4 ft 15/19 7 and NR or / /19 10, 4 ft 15/19 Slide 12

13 ENERGY STAR v3 Insulation at 2009 IECC levels Advanced framing or exterior insulation Sealed top plates and drywall Additional visual inspection checklists Easy to meet thermal enclosure requirements with SIPs Slide 13

14 Builders Challenge Slide 14

15 Advantages of Building with SIPs More cost competitive at higher levels of energy efficiency: Continuous insulation Near perfect air sealing Labor savings Quality Control Seismic Hurricane resistance Long term durability Life cycle analysis Better IAQ Smaller HVAC Occupant comfort Slide 15

16 SIPs: Energy Efficiency Continuous insulation No thermal bridging Total UA alternative method accounts for thermal bridging Performance method Slide 16

17 Code Compliance Prescriptive IECC Walls Total UA Alternative Climate Zone EPS SIPs PU SIPs Prescriptive IECC Roofs Total UA Alternative Climate Zone EPS SIPs PU SIPs /10" Slide 17

18 Code Compliance Prescriptive IECC Walls Total UA Alternative Climate Zone EPS SIPs PU SIPs /8 4 /6 Prescriptive IECC Roofs Total UA Alternative Climate Zone EPS SIPs PU SIPs Slide 18

19 Code Compliance Performance method Whole-house energy modeling Sometimes thinner panels possible Accounts for air infiltration Slide 19

20 Continuous Insulated Panels Meets code requirements for exterior insulation over conventional wood frame walls Slide 20

21 Thermal Bridging Stick SIP Slide 21

22 Air Infiltration Air infiltration part of performance method calculation Responsible for 30 50% of heating and cooling loss Slide 22

23 SIPs: Air Infiltration ORNL test room SIPs vs fiberglass Slide 23

24 SIPs: Air Infiltration Burnside s Inn 0.86 ACH50 HERS 37 EVHA Winner ICF lower level Slide 24

25 SIPs: Air Infiltration Passive House DC 0.6 ACH50 HERS 37 Certified Passive House Slide 25

26 SIPs: Air Infiltration Zero Energy Casita 0.54 ACH50 HERS 33 LEED Platinum, Green Built Texas, Builders Challenge certified, National Green Building Standard Emerald Slide 26

27 SIPs: Air Infiltration Ballard Zero Energy House 0.56 ACH50 HERS -1 Net zero energy Slide 27

28 ZEBRAlliance Research Homes Slide 28

29 ZEBRAlliance Research Homes Walls Attic 2x6, 15% framing factor, flash & batt ½ spray foam + R-19 fiberglass batts 6 SIP with EPS core R-35 cathedral (SIPs 10-in) R-50 cathedral (aged phenolic) 2x12, 24 o.c. Slide 29

30 ZEBRAlliance Research Homes Blower Door Test Results (ACH50) ZEBRA Flash & Batt ZEBRA SIP Slide 30

31 ZEBRAlliance Research Homes Summary SIPs saved 21% more space heating energy than OVF SIPs home HERS 46, OVF home HERS 48 SIPs attained 40% greater air tightness than OVF even though it was the framing crew s first SIP job Crew went to SIPschool, then built same house with OVF SIPS envelope went up in only 5 days compared to 15 for the OVF Slide 31

32 ZEBRAlliance Research Homes Why the large difference in performance? Air leakage Thermal bridging FTC R-Value myth, is it really R-19? ASTM Guarded Hot Box vs Whole Wall R-Value. 75F test temp vs real world. Tightly sealed box not a wall. Slide 32

33 Foam vs Fuzz Fiberglass and other types of fibrous insulation performance decreases as the Delta T increases. Foam insulation performance increases as the Delta T increases. EPS at 75F is 3.85, at 25 is Over 10% increase. Yet the FTC labeling is fixed to the 75F standard. Slide 33

34 SIPs: Labor Savings Independent R.S. Means study shows 55% labor savings over stick frame in residential construction with prefabricated SIPs 11% savings on electrical rough-in Slide 34

35 SIPs: Labor Savings Timber Framing, March, 2012 Second response to article Are SIPs Necessary, March, 2011 Available at Slide 35

36 Cost Savings Faster dry-in time Easier trim installation Faster sheetrock less cutting Waste disposal Shortened duct runs Smaller HVAC Less skilled labor needed Overhead/construction loan Slide 36

37 Wall Systems Study Practical Residential Wall Systems: R-30 and Beyond Robb A. Aldrich, Lois Arena, William Zoeller of Steven Winter Associates, Inc. Examine double wall, foam sheathing, SIPs for R-30 wall construction Slide 37

38 Wall Systems Study Nominal R-Value Whole Wall R- Value Base 2x6 R-20 R-17 $0 12 Double wall R-44 R-42 $1,888 2x4 + 4 ext. insulation R-33 R-33 $3,375 8 EPS SIP R-31 R-28 $1, EPS SIP R-39 R-36 $2,258 Incremental Cost Slide 38

39 Wall Systems Study $4,000 $3,500 $3,000 $2,500 $2,000 $1,500 $1,000 $500 $0 R-30 Wall Systems Cost 12" Double Wall 2x4 + 4" Ext. Insulation 8" EPS SIP 10" EPS SIP Slide 39

40 Building with SIPs Don Ferrier, Ferrier Custom Homes

41 Introduction Ferrier Custom Homes 8 time EVHA Winner NAHB Green Builder Advocate of the Year Texas Green Builder Advocate of the Year NAHB Green Building & Energy Subcommittees 1 st LEED Platinum Home in Texas- 3 rd in Nation Numerous Local & Regional Awards Slide 41

42 Our Clients Two Basic Clients Retiring Baby Boomers Willing to invest to realize long-term savings Young Professionals Right green thing to do Secondary desire to save on energy costs SIP s have been an integral part of meeting the demands of these two groups Slide 42

43 SIPs: Sealing for Air Tightness Slide 43

50 SIPs: Flashing for Air Tightness Slide 50

54 Building Science Corp. Comparisons Heather s Home Fort Worth, Texas SIP Walls Thickness R-Value Payback Period Base Years SIP Roof Thickness R-Value Payback Period Base Years Slide 54

55 Clifton View Homes Cost Study Zero Energy Plans, LLC/Clifton View Homes 4 time EVHA winner 2 time National Green Building Award winner 2011 EVHA Remodeler of the Year 2,000 sq. ft. 2-story home Climate zone Marine 4 15% glazing area Slide 55

56 Clifton View Homes Cost Study 2009 code requirements for Marine 4 climate zone: Walls: R-20 or R-13+R-5 insulated sheathing Roof: R code requirements: Walls: R-20+5 or R-13+R-10 Roof: R-49 Slide 56

57 Clifton View Homes Cost Study Assemblies: 2x6 advanced framing 24 o.c., R-21 fiberglass batts, R-38 attic 2x6 advanced framing 24 o.c., R-21 fiberglass batts, R-5 insulated sheathing, R-49 attic 2x6 advanced framing 24 o.c., closed cell SPF walls and roof 6 SIP wall, 10 SIP roof, EPS core Slide 57

58 Clifton View Homes Cost Study SIPs vs Fiberglass Walls 2009 IECC 2012 IECC 2x6 24 o.c. $18,100 $21,047 SIPs $25,910 $25,910 Cost difference $7,810 $4,863 SIPs vs Spray Foam Walls 2009 IECC 2012 IECC 2x6 24 o.c., SPF $27,616 $27,616 SIPs $25,910 $25,910 Cost difference $-1,706 $-1,706 Slide 58

59 Clifton View Homes Cost Study $30,000 $25,000 $20,000 $15,000 $10,000 $5,000 $ IECC Wood Frame 2012 IECC Wood Frame SIPs 2x6 SPF Slide 59

60 Clifton View Homes Cost Study Because the SIPS are consistent in quality, easy to assemble, deliver predictable results, reduce construction time and waste, and eliminate worries about wall-cavity related moisture issues, I believe the SIPs are by far the better way to build a house. Ted Clifton, Zero Energy Plans/Clifton View Homes Slide 60

61 J. Barrows, Inc. Cost Comparison New York State - Courtesy of John Barrows United Way- Patton St. United Way- Clark St. Custom Homes- Contemporary SF 1,620 1,620 3,153 3,911 Custom Home- Addition Conv Frame $ 62,370 $ 51,870 $ 93,815 $ 86,308 Air Seal/Insul $ 14,730 $ 13,417 $ 30,010 $ 28,366 Cost $ 77,100 $ 65,287 $ 123,825 $ 114,673 Cost/SF $ $ $ $ SIPS Envelope $ 66,595 $ 54,469 $ 111,476 $ 113,026 8 walls 12 roof 6 walls 10 roof 6 walls 10 roof 6 walls 10 roof Cost/SF $ $ $ $ Slide 61

62 J. Barrows, Inc. Cost Comparison $140,000 $120,000 $100,000 $80,000 $60,000 $40,000 Wood Frame SIPs $20,000 $0 United Way Patton St. United Way Clark St. Custom Home Contemporary Custom Home Addition Slide 62

63 J. Barrows, Inc. Cost Comparison Slide 63

64 Presentation and Supporting Documents Available at