www.thefoundationgroup.us RoryHiller@gmail.com The Foundation Group SSIPS vs Concrete Block and Wood Framing The creation of concrete building systems, such as concrete block, when created was a fair choice. Over time new, innovative, Green products started to evolve. The issues with concrete block were many. Concrete block is a porous material and often has issues with sealing. To address this concern one has to add additional material. There are high costs to install, slow construction method, poor R-value without additional insulation, weather dependent during installation. With reference to Wood Framing one has more concerns. Fire, Mold Termites, subject to price swings, labor intensive, quality suspect as wood shrinks and warps. As for energy efficiency the concrete and wood structure would be throwing away $22.00 of every $100.00 dollars. Steel Faced Structural Insulated Panels (Steel Faced SIPs) are high performance building panels used in floors, walls, and roofs for residential and light commercial buildings. The panels are produced by permanently bonding a core of rigid EPS foam plastic insulation between two 26 gauge AZ-50 galvalume metal skins. Steel Faced SIPs are manufactured under factory controlled conditions and can be custom designed for each home. The result is a building system that is extremely strong, energy efficient and cost effective. Building with Steel Faced SIPs will save you time, money and labor. Advantages of SIPS Panels System: Performance SIPS have been used in tens of thousands of structures since 1950 Speed of Construction Using SIPS reduces construction time by 50% - 70% Energy Saving A continuous insulation & vapor envelope reduces energy use significantly. System Strength Our SIPS Panel System will receive Miami-Dade Building approval in Spring 2012. However we are currently building to those specs now which are 150 MPH wind speed and 8.00 seismic. We have recorded our structures withstanding wind speeds of up to 170 MPH and our commercial buildings up to 190 MPH. Environmental SIPS uses EPS foam and G90 Galvaloum. They save energy, reduce air pollution, and minimize jobsite waste. Cost Savings SIPs SAVE MONEY! Please see Diagram: SIPs vs. Concrete Masonry Units (CMUs) vs. Steel 110 Island Way, Clearwater Beach, FL 33767 Office 888-554-9910 Fax 352-397-2808
Structures built with SIPs perform above and beyond traditionally built buildings in numerous ways: SIP structures are significantly more energy efficient than stick built/fiberglass insulation structures. SIP buildings are stronger than stick built structures. Exhaustive laboratory testing has found them to be superior in both sheer resistance and tensile strength. SIP buildings are frequently found to be the only structures left standing after earthquakes, hurricanes, and tornadoes. SIP homes and buildings are significantly quieter than traditionally built structures. Studies have shown that a quieter home or office is a healthier place to be. SIP structures have reduced air infiltration. When ventilated properly, a SIP structure has superior indoor air quality when compared with other traditional building methods. SIP buildings can be erected significantly faster. No other structural framing or insulating is necessary. SIP installation produces significantly less job site waste then traditional building materials. Most of the small amount of waste that is produced can be recycled. Building with SIPs is a sound financial investment. When you factor in labor, waste hauling, and energy savings, SIP structures are comparable to traditionally built homes. In addition, energy efficient SIP homes often have a higher value on the real estate market and often qualify for energy efficient mortgages. Disadvantages of Concrete: Since concrete are porous material, concrete domes often have issues with sealing. If not treated, rainwater can seep through the roof and leak into the interior of the building. On the other hand, the seamless construction of concrete domes prevents air from escaping, and can lead to buildup of condensation on the inside of the shell. Shingling or sealants are common solutions to the problem of exterior moisture, and dehumidifiers or ventilation can address condensation. One main disadvantage of concrete is that all structures made from it will crack at some point. Concrete can also crack as a result of shrinkage, which happens when it dries out. These cracks develop within a few days of laying the structure. This will generally not limit the durability of a structure. Another disadvantage of concrete is its low-thermal conductivity. While concrete is normally used as a layer of fireproofing between walls, it can be badly damaged when exposed to intense heat. The concrete will help to contain the spread of a fire but will become unusable in the process. Concrete also easily corrodes when exposed to seawater. The effects are quick if the concrete is completely submerged for extended periods of time. Concrete can be worn away by waves and by the sand and other materials carried in the ocean.
Why use SIPs instead of conventional methods? SIPs buildings are consistently straighter, thus resulting in faster installation of doors, windows, etc. SIP buildings are finished faster, and thus less interest is paid to the lender. SIPs buildings are, by their very nature, pre-insulated - there's no need to purchase or install additional insulation. Little to no ductwork is required on a SIPs project. Once your electrician is up to speed on SIPs, that phase of the project can happen considerably faster. "Shrinkage" is virtually eliminated - SIP panels don't get "legs" and walk off the jobsite, as excess lumber and insulation can do. A tighter building requires a smaller HVAC system - you will realize DRAMATIC savings as a result, both in the equipment itself and the utility fees down the road. Builders may qualify for a $2,000 federal tax incentive, while the homeowner may also qualify for an additional $1,500. Your building is in the dry faster. Your subcontractors can start - and finish - their work earlier in the project. With SIP panels used for low slope roofs, no venting is required. While air purification systems are often recommended, SIPs buildings will often not require them in many climates, thus eliminating that cost altogether. Not dependant on clear weather Charts and Diagrams: SIPs vs. Concrete Masonry Units (CMUs) vs. Steel - COST REDUCTION A reduction of labor cost can be expected, as well as reduced material costs. Speed of construction will be increased substantially when using Structural Insulated Panels. Installation of a single wall panel section (32ft2) will require no more than 15 minutes with 3 men (.75 man hours). A block mason (exclusive of his laborers) will typically require 3 man hours to complete the same length of wall - a 300% time savings, and even greater labor savings. Typical concrete construction requires cure time allowance at each floor level, while panels do not, ensuring that progression is continuous. Structures built, or clad, with SIPs weigh significantly less than conventionally built structures. Thus, the entire foundation design can be significantly reduced, resulting in marked cost savings. Concrete Masonry Unit walls increase in weight as mass increases. The weight of Fiber Cement SIP walls increase very little as thickness/mass increases, as EPS is the only material that increases in width/mass. The average weight increase for a 4 x 10 panel, in 2 increments, is 7lbs per increment.
Reducing the overall weight of a structure allows for a significant decrease in foundation material, and decreases the elevated weight, allowing superior performance in seismic loading up to 8.0, which significantly decreases cost. By way of example, a direct cost comparison for the foundation on a 2930ft2 ground floor of a two story duplex was calculated. As originally designed, the foundation required 1,670ft3 of concrete. With a revised design, made possible by the use of a SIPs panel system, the same foundation requires only 674ft3 of concrete. In this example, 60% less concrete is required for the revised design. This does not include the CMU block or rebar required as originally designed. Further, the cost reduction carries through the upper floors, requiring a further reduction in concrete and steel. SIPs vs. Concrete Masonry Units (CMUs) vs. Steel - FIRE RATINGS By installing InterCoat in lieu of Drywall we can expect a 5 hour Fire Rating. In the description following the STC table you will note that the addition of materials and wall separation required to achieve the highest STC rating are the same prescribed methods required in the Fire Rating table. This allows two requirements to be addressed with one application. The Fire Rating for CMU Blocks is achieved using formulas which take into account density, aggregate type, and mix ratio; all of these vary from manufacturer to manufacturer. SIPs meet all US Code (IRC) and International Code (ICC) requirements for health and safety, including having been reviewed for fire safety. Fire Rating tests are performed by conducting controlled laboratory burns governed by ASTM - E119 (Standard Test Methods for Fire Tests of Building Construction Materials) and comply with IBC Table 601, ASTM E136 - (Standard Test Method for Behavior of Materials in a Vertical Tube Furnace at 1382º F). SIPs provide ample protection against fire, while simultaneously reducing the cost of materials, and time needed to build, as compared to concrete and cement block.
Is an R-17 SIPs wall comparable to an R-17 Stick Framed wall? When installed, SIPs meet all building codes and pass the American Society for Testing and Materials (ASTM) standards of safety. Fire investigators have found that in buildings constructed of SIPs the panels held up well. For example, in one case where the structure exceeded 1,000 F (538 C) in the ceiling areas and 200 F (93 C) near the floors, most wall panels and much of the ceiling remained intact. An examination of the wall panels revealed that the foam-core had neither melted nor delaminated from the skins. In similar cases, a lack of oxygen seemingly caused the fire to extinguish itself. The air supply in a structural insulated panel home can be quickly consumed in a fire. Lack of skilled construction workers and the amount of time to build are major contributors to the difficulties facing current construction methods. The use of SIPs reduces labor time by 50-70% and construction costs by 40-50%. INTERIOR SURFACE TEMPERATURE - Thermal Lag Masonry homes work on the principal of thermal mass. The masonry product does not have an R- value but does delay the heat transfer through the walls. Thus, interior wall temperature may rise steadily through the daytime, peaking 5 hours later in the evening. In most concrete block buildings, the max heat reaches the inside about 7 p.m. and continues until 10 p.m., often not recovering to the original low temperature. SIP walls resist heat transfer, and thus the interior wall temperature remains fairly constant throughout the day. Heating and cooling load studies have found that heat transmission through walls is the greatest factor in energy loss in buildings, 8% greater than the heat transfer through windows, and 39% greater than transmission through roofs. - Jan Kosny, PhD., R-Value Misconceptions SIP walls are superior to conventional walls in a number of ways. SIPs combine a high insulation R-value with speed and ease of construction.
Advantages of SIPs Reduce labor time by 50-70% and costs by 40-50% Can be erected faster, no structural framing or insulating is required Less job site waste and most can be recycled Miami-Dade Specs of 150MPH Wind Speed and 8.00 Seismic Superior indoor air quality Quieter than traditional structures Does not require cure time for each floor level, progression is continuous Weigh less than conventional structures, foundation design can be reduced Ample protection against fire and reduced cost of materials Resist heat transfer, interior wall temperature remains constant throughout the day Comparison Labor Costs (Example installation of single wall panel section 32ft2): Disadvantages of Concrete Requires cure time allowance at each floor level and is weather dependant Porous material, issues with sealing Rainwater can seep through roof and leak Potential build up of condensation inside of shell All concrete structures will develop cracks within a few days of laying the structure, usually the result of shrinkage when drying Low-thermal conductivity Badly damaged when exposed to intense heat Concrete will become unstable during spread of fire Easily corrodes when exposed to seawater, rapidly when submerged for extended periods of time Can be worn away by waves, sand and other materials carried in the ocean Heat rises steadily throughout the day, max heat reaches inside at 7pm and continues until 10pm SIPS: 15 minutes and three men (300% time savings and even greater labor savings) Concrete: 3 man hours Foundation Comparison (Two story duplex-2930ft2 ground floor): SIPS Requires only 674ft3 of concrete for foundation (60% less) Concrete Requires 1,670ft3 of concrete for foundation In conclusion, The Foundation Group, LLC has developed entirely new innovative and cost effective uses for Steel Structural Insulated Panels (SIPs). Exhaustive man-hours have been invested towards pushing the envelope with our professional architects, engineers and construction savvy team to produce unparalleled plans to meet environmental needs for individual climates and building code requirements. We are environmentally conscious. In addition to SIPS, we provide cutting-edge green technology for construction of residential housing, shelters, commercial, industrial buildings and warehousing. Our exclusive panels have been used for decades and over time have been modified to meet engineering requirements and extremely high standards which have been recognized by the United States Military and numerous countries around the globe.