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Home Innovation Research Labs studied the extended plate and beam wall (EP&B) system during a two-year period from mid-2015 to mid-2017 to determine the wall’s structural performance, moisture durability, constructability, and cost effectiveness for use as a high-R enclosure system for energy code minimum and above-code performance in climate zones 4–8.
A zero energy ready home was recently completed that features an innovative wall system. This highly insulated (high-R) light-frame wall system, called the extended plate and beam, is for use above grade in residential buildings. The Building America research team Home Innovation Research Labs featured this system in a new construction test house.
High-R wall assemblies (R-40 and above) are gaining popularity in the market due to programs like the DOE's Zero Energy Ready Home program, Passive House (PH), Net Zero Energy Home (NZEH) challenges in several states, and highly incentivized retrofit programs. In response to this demand, several builders have successfully used 'double wall' systems to more practically achieve higher R-values in thicker, framed walls. To builders of conventional stick-framed homes, often one of the most appealing features of double wall systems is that there are very few new exterior details. Exterior sheathing, structural bracing, house wrap or building paper, window and door flashing, and siding attachment are usually identical to good details in conventional framed wall systems. The information presented in this guide is intended to reduce the risk of failure in these types of assemblies, increase durability, and result in a reduction of material brought to landfills due to failures and resulting decay. While this document focuses on double wall framing techniques, the majority of the information on how to properly construct and finish high R-value assemblies is applicable to all wall assemblies that do not have foam insulation installed on the exterior of the structural sheathing. The techniques presented have been shown through field studies to reduce the likelihood of mold growth and moisture related damage and are intended for builders, framing contractors, architects, and consultants involved in designing and building super insulated homes.
High-R wall assemblies (R-40 and above) are gaining popularity in the market due to programs like the DOE's Zero Energy Ready Home program, Passive House (PH), Net Zero Energy Home (NZEH) challenges in several states, and highly incentivized retrofit programs. In response to this demand, several builders have successfully used 'double wall' systems to more practically achieve higher R-values in thicker, framed walls. To builders of conventional stick-framed homes, often one of the most appealing features of double wall systems is that there are very few new exterior details. Exterior sheathing, structural bracing, house wrap or building paper, window and door flashing, and siding attachment are usually identical to good details in conventional framed wall systems. The information presented in this guide is intended to reduce the risk of failure in these types of assemblies, increase durability, and result in a reduction of material brought to landfills due to failures and resulting decay. While this document focuses on double wall framing techniques, the majority of the information on how to properly construct and finish high R-value assemblies is applicable to all wall assemblies that do not have foam insulation installed on the exterior of the structural sheathing. The techniques presented have been shown through field studies to reduce the likelihood of mold growth and moisture related damage and are intended for builders, framing contractors, architects, and consultants involved in designing and building super insulated homes.
As more stringent building energy codes and better insulation products combine to yield better performing walls, window efficiency is coming into sharper focus. The U.S. Department of Energy has supported several projects through its national laboratories to improve the thermal performance of windows. At Pacific Northwest National Laboratory (PNNL) in Richland, Washington, the PNNL Lab Homes, two fully monitored identical side-by-side manufactured homes, have been used to test the performance of several window improvements including triple-pane windows, storm windows with low-emissivity (low-e) coatings, smart automated interior insulated shades, and exterior shading products. Findings will be presented on these studies, along with impacts. For example, PNNL’s Lab Home research on low-e storm windows has helped to support a new ENERGY STAR certification, industry standards, and utility incentives. Preliminary findings will also be presented on current Lab Homes experiments focusing on exterior shades. The session will also present findings from related field studies and a market assessment of emerging high-efficiency windows technologies and discuss some of PNNL’s planned field studies that will focus on validating the benefits and costs of the emerging thin triple-pane high-R window.
Neat, densely packed, and highly aligned carbon nanotube fibers (CNTFs) have appealing room-temperature axial thermal conductivity (k) and thermal diffusivity (α) for applications in lightweight heat spreading, flexible thermal connections, and thermoelectric active cooling. Although CNTFs are regularly produced from different input carbon nanotubes (CNTs), prior work has not quantified how the CNT molecular aspect ratio r (i.e., molecular length-to-diameter ratio) influences k and in well-aligned, packed CNTFs. Here, we perform self-heated steady-state and three-omega thermal measurements at room temperature on CNTF suspended in vacuum. Our results show that k increases from 150 to 380 W / mK for viscosity-averaged molecular aspect ratios increasing from r = 960 to 5600 and nanotube diameters of ~2 nm, which we attribute to the effects of thermal resistances between CNT bundles. CNTFs made with varying volume fraction Φ of constituent high-r and low-r CNT have properties that fall within or below the typical macroscopic rule-of-mixtures bounds. The thermal diffusivity α scales with k, leading to a sample-averaged volumetric heat capacity of 1.5 ± 0.3 MJ / m 3 K. This work's findings that fibers made from longer CNT have larger k and α at room temperature motivate further investigation into thermal transport in solution-spun CNTF.
The objective of this project was to explore and potentially develop high performing insulation with increased R/inch and low impact on climate change that would help design highly insulating building envelope systems with more durable performance and lower overall system cost than envelopes with equivalent performance made with materials available today. The proposed technical approach relied on insulation foams with nanoscale pores (about 100 nm in size) in which heat transfer will be decreased. Through the development of new foaming methods, of new polymer formulations and new analytical techniques, and by advancing the understanding of how cells nucleate, expand and stabilize at the nanoscale, Dow successfully invented and developed methods to produce foams with 100 nm cells and 80% porosity by batch foaming at the laboratory scale. Measurements of the gas conductivity on small nanofoam specimen confirmed quantitatively the benefit of nanoscale cells (Knudsen effect) to increase insulation value, which was the key technical hypotheses of the program. In order to bring this technology closer to a viable semi-continuous/continuous process, the project team modified an existing continuous extrusion foaming process as well as designed and built a custom system to produce 6" x 6" foam panels. Dow demonstrated for the first time that nanofoams can be produced in a both processes. However, due to technical delays, foam characteristics achieved so far fall short of the 100 nm target set for optimal insulation foams. In parallel with the technology development, effort was directed to the determination of most promising applications for nanocellular insulation foam. Voice of Customer (VOC) exercise confirmed that demand for high-R value product will rise due to building code increased requirements in the near future, but that acceptance for novel products by building industry may be slow. Partnerships with green builders, initial launches in smaller markets (e.g. EIFS), and efforts to drive cost down will help acceptance in residential and commercial retrofit and new construction.
Transitioning from standard light frame to a thermal mass wall system in a high performance home will require a higher level of design integration with the mechanical systems. The much higher mass in the ICF wall influences heat transfer through the wall and affects how the heating and cooling system responds to changing outdoor conditions. This is even more important for efficient, low-load homes with efficient heat pump systems in colder climates where the heating and cooling peak loads are significantly different from standard construction. This report analyzes a range of design features and component performance estimates in an effort to select practical, cost-effective solutions for high performance homes in a cold climate. Of primary interest is the influence of the ICF walls on developing an effective air sealing strategy and selecting an appropriate heating and cooling equipment type and capacity. The domestic water heating system is analyzed for costs and savings to investigate options for higher efficiency electric water heating. A method to ensure mechanical ventilation air flows is examined. The final solution package includes high-R mass walls, very low infiltration rates, multi-stage heat pump heating, solar thermal domestic hot water system, and energy recovery ventilation. This solution package can be used for homes to exceed 2012 International Energy Conservation Code requirements throughout all climate zones and achieves the DOE Challenge Home certification.
Home Innovation Research Labs studied the extended plate and beam wall (EP&B) system during a two-year period from mid-2015 to mid-2017 to determine the wall’s structural performance, moisture durability, constructability, and cost effectiveness for use as a high-R enclosure system for energy code minimum and above-code performance in climate zones 4–8.
To effectively mitigate prevailing perceptions of potential moisture risks in high-R wall assemblies, a comprehensive moisture durability assessment that incorporates BA team field evaluations, lab tests and simulations has been completed over the last couple years. In FY18, three stick-built walls were succumbed to typical Chicago weather in ORNL’s Heat, Air and Moisture chamber. The measured temperature, relative humidity and moisture content within these walls were compared to WUFI hygrothermal simulation results. In FY19, similar experiments and comparison to WUFI results were completed with two walls, a Structural Insulated Panel (SIP) based wall and a Concrete Masonry Unit (CMU) based wall. The following tasks were completed for these two walls: 1. Measure air permeance of each individual wall using ASTM E283 Standard Test Method. 2.Test walls in diffusion scenario as only moisture transport mechanism and compare measured transient temperature and relative humidity of select wall components to WUFI model results. Chicago summer and weather will be investigated. 3. Test walls in wetting event scenario and compare measured transient temperature and relative humidity of select wall components with Chicago summer weather to WUFI model results. 4. Test walls in diffusion/advection scenario. In addition to controlling outdoor chamber to match real outdoor weather, a pressure differential across the wall will be varied. Measured transient temperature and relative humidity of select wall components will be compared to WUFI model results. 5. Test walls in diffusion/advection with solar heating of cladding. In addition to the variables above, IR lamps will be used to heat the cladding on a diurnal cycle. Measured transient OSB MC and temperature will be compared to WUFI model results. This report documents the experimental method, results and comparison of the measured experimental hygrothermal performance of the two walls to simulations results.
Transitioning from standard light frame to a thermal mass wall system in a high performance home will require a higher level of design integration with the mechanical systems. The much higher mass in the ICF wall influences heat transfer through the wall and affects how the heating and cooling system responds to changing outdoor conditions. This is even more important for efficient, low-load homes with efficient heat pump systems in colder climates where the heating and cooling peak loads are significantly different from standard construction.This report analyzes a range of design features and component performance estimates in an effort to select practical, cost-effective solutions for high performance homes in a cold climate. Of primary interest is the influence of the ICF walls on developing an effective air sealing strategy and selecting an appropriate heating and cooling equipment type and capacity. The domestic water heating system is analyzed for costs and savings to investigate options for higher efficiency electric water heating. A method to ensure mechanical ventilation air flows is examined. The final solution package includes high-R mass walls, very low infiltration rates, multi-stage heat pump heating, solar thermal domestic hot water system, and energy recovery ventilation. This solution package can be used for homes to exceed 2012 International Energy Conservation Code requirements throughout all climate zones and achieves the DOE Challenge Home certification.
The Department of Energy (DOE) and Oak Ridge National Laboratory (ORNL) have developed an innovative new design tool that will put building science expert advice in the hands of every building designer who cares to manage moisture risk in high-R envelope components. As modern buildings become increasingly more airtight, constructed with modern labor-saving materials, and equipped with air-conditioning, they have become less forgiving to moisture intrusion. The Building Science Advisor (BSA) provides building science knowledge and advice based on expert experience, field measurements, laboratory tests, and computer simulations.BSA users are prompted to enter relevant information about the building location, design, and material selection options like cladding, structural system, and insulation. Influential factors such as climate, building air tightness, material properties, and internal moisture loads are also considered to estimate and compare the moisture durability performance of several design options. If the BSA deems the assembly’s performance unsatisfactory, it will provide the reasons why, and suggest necessary changes to wall design to ensure more robust performance.Using the BSA tool enables building designers to confidently select assembly design characteristics that achieve their design goals with the least moisture durability risk. Links to design-specific guidance are also be provided to help users manage any remaining risk. This tool will further enable DOE’s Building Technologies Office (BTO) to meet its long-term energy goal of a 50% reduction in building energy consumption by reducing builder concern about using highly energy efficient wall systems.
This report is the second report on the Wyandotte NSP2 project in Wyandotte, MI and documents refinements to the design, construction, and quality control for the High R-value enclosure. The report will be of interest to designers and builders of production housing in Cold Climates. The focus of the second round of research was on using the hybrid insulation approach to develop a reliable methodof achieving consistently low airtightness numbers. There are two primary outcomes from this research. First, the airtightness measurements demonstrate that with a shallow learning curve, even new builders entering the program having little experience with the technology package are able to achieve consistent results that are less than 1.5 ACH50. Second, the process changes implemented to helpsecure these results were straightforward and ended up encouraging better communication between designer, builder, and the City officials supervising the project.
This report is the second report on the Wyandotte Neighborhood Stabilization Program 2 project in Wyandotte, MI, and documents refinements to the design, construction, and quality control for the high R-value enclosure. The report will be of interest to designers and builders of production housing in Cold Climates. The focus of the second round of research was on using the hybrid insulation approach to develop a reliable method of achieving consistently low airtightness numbers. There are two primary outcomes from this research. First, the airtightness measurements demonstrate that with a shallow learning curve, even new builders entering the program having little experience with the technology package are able to achieve consistent results that are less than 1.5 ACH50. Second, the process changes implemented to help secure these results were straightforward and ended up encouraging better communication between designer, builder, and the city officials supervising the project.
High R-value wall assemblies (R-40 and above) are gaining popularity in the market due to programs such as the U.S. Department of Energy Zero Energy Ready Home program, Passive House, Net Zero Energy Home challenges in several states, and highly incentivized retrofit programs. In response to this demand, several builders have successfully used double-wall systems to achieve higher R-values in thicker, framed walls. To builders of conventional stick-framed homes, often one of the most appealing features of double-wall systems is that there are very few new exterior details. Exterior sheathings, structural bracings, house wraps or building paper, window and door flashings, and siding attachments are usually identical to good details in conventional framed-wall systems. However, although the details in double-wall systems are very similar to those in conventional stick framing, there is sometimes less room for error. Several studies have confirmed colder temperatures of exterior sheathing in high R-value wall assemblies that do not have exterior rigid foam insulation. These colder temperatures can lead to increased chances for condensation from air exfiltration, and they have the potential to result in moisture-related problems (Straube and Smegal 2009, Arena 2014, Ueno 2015). The information presented in this guide is intended to reduce the risk of failure in these types of assemblies, increase durability, and reduce material brought to landfills due to failures and resulting decay. Although this document focuses on double-wall framing techniques, the majority of the information about how to properly construct and finish high R-value assemblies is applicable to all wall assemblies that do not have foam insulation installed on the exterior of the structural sheathing. The techniques presented have been shown through field studies to reduce the likelihood of mold growth and moisture-related damage and are intended for builders, framing contractors, architects, and consultants involved in designing and building super-insulated homes. The information is applicable to both new construction and gut-rehabilitation projects in Climate Zones 5 and higher.
In recent years, improvements in glass manufacturing have allowed the production of thin triple-pane windows, which are manufactured with a thickness similar to standard double-pane windows. Because this highly insulating “thin triple” glass product can be incorporated into almost any existing window frame and can be fabricated at a modest added cost, the U.S. Department of Energy is sponsoring laboratory and field demonstration testing of thin triple-pane windows to validate thermal performance and installation requirements in real-life field settings. To examine the performance of thin triple-pane windows, the Pacific Northwest National Laboratory (PNNL) evaluated the windows at the PNNL Lab Homes, a matched pair of homes located on PNNL’s campus in Richland, Washington. In this study, one Lab Home contained a complete set of nine thin triple-pane windows, while the other Lab Home contained baseline double-pane windows. The Lab Homes experiments demonstrated significant that replacing clear glass double-pane windows with thin triple-pane windows provided year-round energy savings and reduced peak demand both in the heating and cooling seasons. The Lab Homes experiments also validated other performance benefits of the thin triple-pane windows including reduced condensation potential, more even temperatures throughout the home and near the windows, and reduced sound attenuation through the windows, leaving the home quieter and more comfortable for the occupants.
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Sales of high-performance triple-pane windows make up only a small fraction (~3%) of total window sales in the United States with relatively stagnant market growth over the past 20 years. High costs have been the most commonly cited barrier to adoption. The emergence of thin triples that can fit into the glazing pocket of existing double pane windows has the potential to revolutionize the high-performance window market in particular the retrofit market by enabling glass only upgrades for situations where the frames are still in good condition. The retrofit market has other unique challenges not found in new construction that can be solved or reduced by thin triple pane windows. Insert replacements are often pursued instead of full frame replacement, in retrofits, this method reduces the net free area of a window and can turn an egress window into one that no longer meets the net free area requirements for egress. Thin frames minimize such occurrences. However, these thin frames can often not accommodate the weight of a traditional triple pane, thin triples can bring high performance to this situation. Thicker frames can also increase retrofit labor costs because the interior drywall and/or trim molding needs to be cut back to accommodate a thicker frame while thin triples can fit into frames that match the thickness of the existing window. This paper presents information about field test experiences the highlight these retrofit advantages from experiencing the challenges associated with retrofitting a thick frame as well as the supply chain, purchasability, material and labor costs, and real-world energy and non-energy performance associated with the IGU only replacement method.