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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Report of the Panel on Aerodynamics

Progress in aerodynamics over the past 50 years has been evidenced by the development of increasingly sophisticated and efficient flight vehicles throughout the flight spectrum. Advances have generally arisen in an evolutionary manner from experience gained in wind tunnel testing, flight testing, and improvements in analytical and computational capabilities. As a result of this evolutionary development, both military and commercial vehicles operate at a relatively high efficiency level. This observation plus the fact that airplanes have not changed appreciably in outward appearance over recent years has led some skeptics to conclude incorrectly that aerodynamics is a mature technology, with little to be gained from further developments in the field. It is of interest to note that progress in aerodynamics has occurred without a thorough understanding of the fundamental physics of flow, turbulence, vortex dynamics, and separated flow, for example. The present understanding of transition, turbulence, and boundary layer separation is actually very limited. However, these fundamental flow phenomena provide the key to reducing the viscous drag of aircraft. Drag reduction provides the greatest potential for increased flight efficiency from the standpoint of both saving energy and maximizing performance. Recent advances have led to innovative concepts for reducing turbulent friction drag by modifying the turbulent structure within the boundary layer. Further advances in this basic area should lead to methods for reducing skin friction drag significantly. The current challenges for military aircraft open entirely new fields of investigation for the aerodynamicist. The ability through very high speed information processing technology to totally integrate the flight and propulsion controls can permit an aircraft to fly with "complete abandon," avoiding departure, buffet, and other undesirable characteristics. To utilize these new control concepts, complex aerodynamic phenomena will have to be understood, predicted, and controlled. Current requirements for military aircraft include configuration optimization through a widened envelope from subsonic to supersonic and from low to high angles of attack. This task is further complicated by requirements for control of observables. These challenging new designs do not have the luxury of a large experimental data base from which to optimize for various parameter combinations. Consequently, there exists a strong need for better techniques, both experimental and computational, to permit design optimization in a complete sense.

Bradley, Richard G.↗
NASA NTRS2005

Modern Radar Techniques for Geophysical Applications: Two Examples

The last decade of the evolution of radar was heavily influenced by the rapid increase in the information processing capabilities. Advances in solid state radio HF devices, digital technology, computing architectures and software offered the designers to develop very efficient radars. In designing modern radars the emphasis goes towards the simplification of the system hardware, reduction of overall power, which is compensated by coding and real time signal processing techniques. Radars are commonly employed in geophysical radio soundings like probing the ionosphere; stratosphere-mesosphere measurement, weather forecast, GPR and radio-glaciology etc. In the laboratorio di Geofisica Ambientale of the Istituto Nazionale di Geofisica e Vulcanologia (INGV), Rome, Italy, we developed two pulse compression radars. The first is a HF radar called AIS-INGV; Advanced Ionospheric Sounder designed both for the purpose of research and for routine service of the HF radio wave propagation forecast. The second is a VHF radar called GLACIORADAR, which will be substituting the high power envelope radar used by the Italian Glaciological group. This will be employed in studying the sub glacial structures of Antarctica, giving information about layering, the bed rock and sub glacial lakes if present. These are low power radars, which heavily rely on advanced hardware and powerful real time signal processing. Additional information is included in the original extended abstract.

Arokiasamy, B. J.↗
DOE OSTI2022

Residential Façade Upgrades: Market Assessment and Recommendations

In support of DOE’s move toward transformational whole-building upgrades and enclosure solutions, the Pacific Northwest National Laboratory (PNNL) and National Renewable Energy Laboratory (NREL) are partnering and collaborating with leading building science researchers and home-performance entities to identify and characterize technical and economic barriers to façade retrofits in an effort to identify market-viable façade solutions and opportunities for an actionable plan to transform the market. The project includes partnerships with Building Science Corporation (BSC) and a combination of strategic implementation partners with home-performance and retrofit expertise and industry contacts. The project will include expert advisory and review consultation from Lawrence Berkeley National Laboratory’s (LBNL’s) Residential Windows & Attachments team and Oak Ridge National Laboratory’s Building Envelope team. The project consists of three parts: 1. a market analysis that captures the current state of the façade retrofit market and includes housing characteristics and retrofit costs, façade retrofit approaches and materials, contractor business models and workforce requirements to support advanced façade approaches; 2. an economic analysis focused on the viability of advanced façade retrofit approaches and materials; and 3. field demonstration of façade retrofits that include enhanced insulation/air-sealing and window technologies in multiple climate zones. This report represents the market analysis, as outlined in item 1 above. The goal of this analysis is to provide a techno-economic study that supports comprehensive retrofits of residential enclosures that include traditional approaches, and integrated wall assemblies and windows that result in durable, energy efficient, and marketable strategies. This study will provide a better knowledge base regarding the viable market for façade retrofit strategies, identify the barriers to uptake, analyze economic opportunities, and develop documentation specifically aimed to overcome technical and market barriers associated with installation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1995

High Pressure Earth Storable Rocket Technology Program: Basic Program

The HIPES Program was conducted for NASA-LeRC by TRW. The Basic Program consisted of system studies, design of testbed engine, fabrication and testing of engine. Studies of both pressure-fed and pump-fed systems were investigated for N2O4 and both MMH and N2H4 fuels with the result that N2H4 provides the maximum payload for all satellites over MMH. The higher pressure engine offers improved performance with smaller envelope and associated weight savings. Pump-fed systems offer maximum payload for large and medium weight satellites while pressure-fed systems offer maximum payload for small light weight satellites. The major benefits of HIPES are high performance within a confined length maximizing payload for lightsats which are length (volume) constrained. Three types of thrust chambers were evaluated -- Copper heatsink at 400, 500 and 600 psia chamber pressures for performance/thermal; water cooled to determine heat absorbed to predict rhenium engine operation; and rhenium to validate the concept. The HIPES engine demonstrated very high performance at 50 lbf thrust (epsilon = 150) and Pc = 500 psia with both fuels: Isp = 337 sec using N2O4-N2H4 and ISP = 327.5 sec using N2O4-MMH indicating combustion efficiencies greater than 98%. A powder metallurgy rhenium engine demonstrated operation with high performance at Pc = 500 psia which indicated the viability of the concept.

Chazen, M. L.↗
NASA NTRSDate not supplied

High-Altitude ADS-B/GPS LPV Flight Tests on a NASA ER-2 Research Airplane

The research presented in this paper describes the conceptual design of a system architecture that integrates Automatic Dependent Surveillance-Broadcast (ADS-B) and Global Positioning System (GPS) Localizer Performance Vertical (LPV) guidance technology onto a unique high-altitude research airplane: a United States Air Force (USAF) / Lockheed Martin (Bethesda, Maryland) Aeronautics U-2S airplane. The design features modern display capabilities to provide air-to-air surveillance and precision navigation, to adhere to Federal Aviation Administration (FAA) certification standards for operations in upper Class E airspace. The National Aeronautics and Space Administration (NASA) variant of the U-2S, now called the Earth Resources (ER-2) airplane, remains unrivaled in the art of sustained high-altitude flight for scientific expeditions. Capable of routinely cruising above flight level (FL) 650 that had been considered, at inception, the domain of only the most elite experimental research aircraft types. Nicknamed the Dragon Lady, this U-2S research testbed is still one of the most advanced aircraft in the world. The exceptional military design of the vehicle, security guidelines, and the performance envelope of the ER-2 posed unique challenges to the integration of modern civilian avionics. ADS-B epitomizes the next generation of surveillance technology, incorporating both air and ground aspects. ADS-B provides air traffic control (ATC) with a more accurate picture of the three-dimensional positioning of aircraft in various phases of flight, including en route, terminal, approach, and ground operations. The airborne surveillance system broadcasts its identification, position, altitude, velocity, and other information. GPS LPV represents a significant advancement in aviation technology, emphasizing the pivotal role that GPS and Performance-Based Navigation concepts will play in the foreseeable future. This technology represents a shift from sensor-based navigation to performance-based navigation, allowing for more flexible and efficient use of airspace. This research described herein is structured as follows: Section II, “Systems Background,” provides a systems background and description of an ADS-B and GPS LPV system equipped on the high-altitude ER-2 research airplane to satisfy the FAA airworthiness requirements for high-altitude flight operations. Section III, “Flight Test System,” describes the flight-test airplane systems. Section IV, “Analysis of GPS SBAS, Safety, and Ground Tests,” provides an overview of the GPS Satellite-Based Augmentation System (SBAS) and an analysis of the GPS LPV metrics, safety, and ground tests. Section V, “High-Altitude Flight Tests,” describes the high-altitude flight tests, including 3 flight-test results, analysis, human factors, and lessons learned. Section VI, the conclusion, draws insights from the lessons learned, discusses the design challenges associated with ADS-B and GPS LPV, and showcases the paramount significance of these pivotal technologies in aircraft surveillance and navigation.

Ricardo A. Arteaga↗
DOE OSTI2025

Benefits of Dual Fuel Heat Pump Grid-responsive Control: A Model-based Control Optimization Approach Using Building and Equipment Co-simulation

Conventional dual fuel heat pumps lack the intelligent control mechanisms to efficiently manage the switch between heat pump and furnace, leading to sub-optimal energy usage and, in some cases, increased operating costs. To resolve this gap, this study applies optimized control on hybrid heat pumps. With a focus on equipment control strategies, we compare the performances of five spacing heating equipment, including a conventional heat pump (HP), a conventional furnace, a dual fuel heat pump (DFHP) with conventional control, a dual fuel heat pump with smart control, and a novel seamlessly fuel flexible heat pump (SFFHP). While DFHP runs on either gas or electricity at any given moment, SFFHP concurrently consumes gas and electricity by continuously optimizing the proportion of each. In this research, a co-simulation framework is developed by integrating a building envelope model with a physics-based heat pump simulation model to analyze the benefits of grid-responsive controls of DFHP and SFFHP. The model-based optimal controls adjust the operation of the heat pump and gas furnace based on utility price signals and marginal grid emission to minimize utility cost and CO 2 emissions for multiple climate zones, different utility tariffs, and marginal grid emission scenarios. Case studies in Chicago and Los Angeles demonstrate that SFFHP and DFHP, with model-based optimal control, can deliver significant reductions in peak demand, utility cost, and CO 2 emission. In Chicago, SFFHP and smart controlled DFHP yield up to 64.7% and 61.7% utility cost reduction and up to 15.7% and 8.5% CO 2 emission reduction compared to the gas furnace. In Los Angeles, SFFHP and smart controlled DFHP achieve up to 43.6% and 40.1% utility cost reduction and up to 13.8% and 14.1% CO2 emission reduction compared to conventional heat pumps. In conclusion, by leveraging the fuel flexibility nature of dual fuel heat pumps, the model-based control optimization approach makes dual fuel heat pump an attractive option for demand response programs.

Control↗
DOE OSTI2023

Centering Energy and Environmental Justice in the Buildings Energy Sector

We face incredible challenges for decarbonizing our economy and raising the standard of living for all members of our society at the same time. Historical energy efficiency efforts have been effective in making small steps, but they fall far short of the massive changes we need to make, and they completely miss helping communities of disadvantage (e.g. low-income, African American, Hispanic American, Native American and tribal nations, etc). Business as usual efforts do not take the time to connect with and understand the challenges of these historical underinvested communities and therefore have not been effective at helping these communities. The Biden Harris Administration has set ambitious goals for decarbonization of our economy that include a requirement that 40% of efforts support energy and environmental justice communities. If we are to meet our decarbonization goals, it is imperative that we change our approach to research, development, and deployment of new technologies. The Department of Energy has set energy justice as a priority and is working with the national laboratories to change our approaches. This paper starts with definitions of what we mean by energy and environmental justice and how they apply to building technologies and deployment efforts. We provide several examples of how historical efforts have succeeded and how they have failed to account for challenges of communities of disadvantage. We identify market and technology barriers to decarbonization and energy efficiency for specific technologies and how these barriers are exacerbated for disadvantaged communities. From these examples, we propose a new framework for integrating energy and environmental justice into all aspects of technology development, deployment, and policy efforts within the building energy sector.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2013

Energy and Energy Cost Savings Analysis of the IECC for Commercial Buildings

The purpose of this analysis is to assess the relative energy and energy cost performance of commercial buildings designed to meet the requirements found in the commercial energy-efficiency provisions of the International Energy Conservation Code (IECC). Section 304(b) of the Energy Conservation and Production Act (ECPA), as amended, requires the Secretary of Energy to make a determination each time a revised version of ASHRAE Standard 90.1 is published with respect to whether the revised standard would improve energy efficiency in commercial buildings. As many states have historically adopted the IECC for both residential and commercial buildings, PNNL has evaluated the impacts of the commercial provisions of the 2006, 2009, and 2012 editions of the IECC. PNNL also compared energy performance with corresponding editions of ANSI/ASHRAE/IES Standard 90.1 to help states and local jurisdictions make informed decisions regarding model code adoption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2013

Applying Best Practices to Florida Local Government Retrofit Programs

In some communities, local government and non-profit entities have funds to purchase and renovate distressed, foreclosed homes for resale in the affordable housing market. Numerous opportunities to improve whole house energy efficiency are inherent in these comprehensive renovations. BA-PIRC worked together in a multiyear field study making recommendations in individual homes, meanwhile compiling improvement costs, projected energy savings, practical challenges, and labor force factors surrounding common energy-related renovation measures. The field study, Phase 1 of this research, resulted in a set of best practices appropriate to the current labor pool and market conditions in central Florida to achieve projected annual energy savings of 15%-30% and higher. This report describes Phase 2 of the work where researchers worked with a local government partner to implement and refine the "current best practices". A simulation study was conducted to characterize savings potential under three sets of conditions representing varying replacement needs for energy-related equipment and envelope components. The three scenarios apply readily to the general remodeling industry as for renovation of foreclosed homes for the affordable housing market. The new local government partner, the City of Melbourne, implemented the best practices in a community-scale renovation program that included ten homes in 2012.

30% savings↗
DOE OSTI2023

A systematic review of building energy sufficiency towards energy and climate targets

Among the sufficiency, efficiency, and renewable frameworks for reducing energy use and energy-related carbon emissions, Building Energy Sufficiency (BES) is gaining attention from policy makers and engineers. Despite the significant role of the building sector in the success of national energy and climate plans, there is a lack of research on the drivers, technologies, and effective policy instruments required to achieve BES in the building operational phase. To fill this gap, this study presents a systematic review of the definition and paradigm of BES and concludes that BES should address both occupant demand and energy or emissions requirements simultaneously. The characteristics of occupant demand in building services are divided into four dimensions: time and space, quality and quantity, control and adjustment, and flexibility. Technical options regarding the building architecture, the envelope system, and the building energy system are reviewed. Finally, policy implications and recommendations are discussed. As a result, the multiple benefits and multidisciplinary nature of BES justify further research and accelerated policy implementation in developed and developing countries.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2018

Characterization of a 100-kW Class Nested-Channel Hall Thruster

The next generation of electric propulsion consists of systems in excess of 300 kW of power. These systems enable a wide variety of missions, including crewed missions to near-Earth asteroids and Mars. Hall thrusters are a particularly attractive technology for these missions, but development and demonstration of 100-kW class devices has been limited to date. Here, a 100-kW class three-channel nested Hall thruster called the X3 was operated up to 102 kW total discharge power. The three channels of the X3 can be operated in any combination, providing seven unique configurations and a total throttling envelope of 2-200 kW. Previous testing of the X3 was limited to 30 kW and found that it was not providing state-of-the-art performance.Two low-power test campaigns were completed at the University of Michigan which identified potential mechanisms for this under-performance. Improvements to the thruster were made before a high-power performance characterization at NASA Glenn Research Center. There, the X3 was fired on xenon propellant from 5-102 kW total power. The thruster demonstrated stable operation in all seven channel combinations at discharge voltages from 300 V to 500 V and three different current densities. All seven channel combinations demonstrated similar performance at a given discharge voltage and current density. The largest thrust recorded was 5.4 N, and total efficiency and specific impulse ranged from 0.54 to 0.67 and 1800 seconds to 2650 seconds, respectively.In addition to the performance measurements, a suite of plasma diagnostics and a high-speed camera were used to study the operation of the thruster in greater detail. The probe results are compared against those in the literature and demonstrate that the X3, even in multi-channel operation, is producing similar charge, mass, current, and voltage utilization efficiencies as state of the art single-channel Hall thrusters. High-speed camera analysis identified that the X3 operated with similar discharge current oscillations at all conditions tested. Additionally, a preliminary calculation of cross-channel ingestion and its effect on thruster efficiency is made. This work represents the highest total power (102 kW), thrust (5.4 N), and discharge current (247 A) demonstrated by a Hall thruster to date, improvements of 6 percent, 64 percent, and 119 percent respectively over previous values. These results are discussed in the context of continued high-power Hall thruster development and future mission applications.

Hall, Scott James↗
DOE OSTI2014

Existing Whole-House Solutions Case Study: Applying Best Practices to Florida Local Government Retrofit Programs - Central Florida

In some communities, local government and non-profit entities have funds to purchase and renovate distressed, foreclosed homes for resale in the affordable housing market. Numerous opportunities to improve whole house energy efficiency are inherent in these comprehensive renovations. BA-PIRC worked together in a multiyear field study making recommendations in individual homes, meanwhile compiling improvement costs, projected energy savings, practical challenges, and labor force factors surrounding common energy-related renovation measures. The field study, Phase 1 of this research, resulted in a set of best practices appropriate to the current labor pool and market conditions in central Florida to achieve projected annual energy savings of 15%-30% and higher. This case study describes Phase 2 of the work where researchers worked with a local government partner to implement and refine the "current best practices". A simulation study was conducted to characterize savings potential under three sets of conditions representing varying replacement needs for energy-related equipment and envelope components. The three scenarios apply readily to the general remodeling industry as for renovation of foreclosed homes for the affordable housing market. The new local government partner, the City of Melbourne, implemented the best practices in a community-scale renovation program that included ten homes in 2012.

30% savings↗
DOE OSTI2013

Applying Best Practices to Florida Local Government Retrofit Programs

In some communities, local government and non-profit entities have funds to purchase and renovate distressed, foreclosed homes for resale in the affordable housing market. Numerous opportunities to improve whole house energy efficiency are inherent in these comprehensive renovations. BA-PIRC worked together in a multi-year field study making recommendations in individual homes, meanwhile compiling improvement costs, projected energy savings, practical challenges, and labor force factors surrounding common energy-related renovation measures. The field study, Phase 1 of this research, resulted in a set of best practices appropriate to the current labor pool and market conditions in central Florida to achieve projected annual energy savings of 15-30% and higher. This report describes Phase 2 of the work where researchers worked with a local government partner to implement and refine the 'current best practices.' A simulation study was conducted to characterize savings potential under three sets of conditions representing varying replacement needs for energy-related equipment and envelope components. The three scenarios apply readily to the general remodeling industry as for renovation of foreclosed homes for the affordable housing market. Our new local government partner, the City of Melbourne, implemented the best practices in a community-scale renovation program that included ten homes in 2012.

30% SAVINGS↗
DOE OSTI2014

Applying Best Practices to Florida Local Government Retrofit Programs, Central Florida (Fact Sheet)

In some communities, local government and non-profit entities have funds to purchase and renovate distressed, foreclosed homes for resale in the affordable housing market. Numerous opportunities to improve whole house energy efficiency are inherent in these comprehensive renovations. BA-PIRC worked together in a multi-year field study making recommendations in individual homes, meanwhile compiling improvement costs, projected energy savings, practical challenges, and labor force factors surrounding common energy-related renovation measures. The field study, Phase 1 of this research, resulted in a set of best practices appropriate to the current labor pool and market conditions in central Florida to achieve projected annual energy savings of 15-30% and higher. This report describes Phase 2 of the work where researchers worked with a local government partner to implement and refine the "current best practices". A simulation study was conducted to characterize savings potential under three sets of conditions representing varying replacement needs for energy-related equipment and envelope components. The three scenarios apply readily to the general remodeling industry as for renovation of foreclosed homes for the affordable housing market. Our new local government partner, the City of Melbourne, implemented the best practices in a community-scale renovation program that included ten homes in 2012.

30% SAVINGS↗
NASA NTRS1998

Initial Flight Test Evaluation of the F-15 ACTIVE Axisymmetric Vectoring Nozzle Performance

A full envelope database of a thrust-vectoring axisymmetric nozzle performance for the Pratt & Whitney Pitch/Yaw Balance Beam Nozzle (P/YBBN) is being developed using the F-15 Advanced Control Technology for Integrated Vehicles (ACTIVE) aircraft. At this time, flight research has been completed for steady-state pitch vector angles up to 20' at an altitude of 30,000 ft from low power settings to maximum afterburner power. The nozzle performance database includes vector forces, internal nozzle pressures, and temperatures all of which can be used for regression analysis modeling. The database was used to substantiate a set of nozzle performance data from wind tunnel testing and computational fluid dynamic analyses. Findings from initial flight research at Mach 0.9 and 1.2 are presented in this paper. The results show that vector efficiency is strongly influenced by power setting. A significant discrepancy in nozzle performance has been discovered between predicted and measured results during vectoring.

Orme, John S.↗
NASA NTRS2019

Bounding Methods for Heterogeneous Lidar-derived Navigational Geofences

Safe Unmanned Aerial Vehicle (UAV) operations near the ground require navigation methods that avoid fixed obstacles such as buildings, power lines and trees. Aerial lidar surveys of ground structures are available with the precision and accuracy to geolocate obstacles, but the high volume of raw survey data can exceed the compute power of onboard processors and the rendering ability of ground-based flight planning maps. Representing ground structures with bounding polyhedra instead of point clouds greatly reduces the data size and can enable effective obstacle avoidance, as long as the bounding geometry envelopes the structures with high spatial fidelity. This report describes in detail four methods to compute bounding geometries of ground obstacles from lidar point clouds. The four methods are: 1) 2.5D Maximum Elevation Box, 2) 2.5D Ground Map Extrusion, 3) 3D Bounding Cylinder, and 4) 3D Bounding Box. The methods are applied to five point cloud datasets from lidar surveys of UAV flight research sites in Georgia and Virginia with an average point spacing that ranges from 0.1m to 0.6m. The methods are assessed using survey areas with geometrically heterogeneous ground structures: buildings, vegetation, power lines, and sub-meter structures such as road signs and guy wires. The 2.5D Maximum Elevation Box method is useful for simple structures. The 2.5D Ground Map Extrusion method efficiently encloses vegetation, but requires handdrawn ground footprints. The 3D Bounding Cylinder method excels at enclosing linear structures such as power lines and fences. The 3D Bounding Box method excels at enclosing planar structures such as buildings. The methods are compared on the basis of data compression and boundary fidelity on selected areas. The 2.5D methods yield the highest data compression but the polyhedra produced by them enclose significant amounts of empty space. Boundary fidelity is superior for the 3D methods, though this fidelity comes at the cost of a roughly thirtyfold lower data compression ratio than the 2.5D Maximum Elevation Box method. A mix of these output geometries is proposed for autonomous UAV navigation with limited on-board computing. Both the accuracy and spatial detail of emerging satellite-based survey technology lower than that of aerial lidar scanning survey technology. Sub-meter structures and thin linear structures are not reliably mapped at present by satellite-based surveys.

Moore, Andrew J.↗
NASA NTRS1990

Seamless metal-clad fiber-reinforced organic matrix composite structures and process for their manufacture

A metallic outer sleeve is provided which is capable of enveloping a hollow metallic inner member having continuous reinforcing fibers attached to the distal end thereof. The inner member is then introduced into outer sleeve until inner member is completely enveloped by outer sleeve. A liquid matrix member is then injected into space between inner member and outer sleeve. A pressurized heat transfer medium is flowed through the inside of inner member, thereby forming a fiber reinforced matrix composite material. The wall thicknesses of both inner member and outer sleeve are then reduced to the appropriate size by chemical etching, to adjust the thermal expansion coefficient of the metal-clad composite structure to the desired value. thereby forming a fiber reinforced matrix composite material. The wall thicknesses of both inner member and outer sleeve are then reduced to the appropriate size by chemical etching, to adjust the thermal expansion coefficient of the metal-clad composite structure to the desired value. The novelty of this invention resides in the development of a efficient method of producing seamless metal clad fiber reinforced organic matrix composite structures.

Bluck, Raymond M.↗
DOE OSTI2025

Benefits Of Automated Construction And Energy Efficiency Measures In Modular Homes

This article builds on and adds to a Buildings XV publication that introduced the Transformative Efficiency and Automation in Modular Homes (TEAMH) project. The TEAMH project sought to develop a scalable solution for producing modular homes with 20-50% energy savings and similar cost relative to site-fabricated single-family home construction. A key aspect of the project was assessing the potential for labor cost reductions through automation-assisted construction using light gauge steel (LGS). To quantify the advantages of this approach, side-by-side comparisons were made between traditional wood-framed construction and automation-assisted LGS construction. This demonstration involved constructing one wood-framed wall and several LGS test walls, accompanied by a time-and-motion study. The results indicated that automation assistance could decrease construction time and associated labor costs by as much as 46%. High-performance envelope technologies for exterior insulation and air sealing were evaluated to compare modular homes with site-built homes that meet the International Energy Conservation Code (IECC). A key technology considered was vacuum insulation panels (VIPs) with fiberglass cores. Guarded hot box testing of multiple full-scale wall assemblies containing different combinations of exterior continuous insulation systems containing phenolic foam and VIPs. Testing on various full-scale wall assemblies revealed that, with LGS construction, cavity insulation had minimal impact on exterior wall performance. Omitting cavity insulation can reduce labor and material costs while streamlining manufacturing, as its installation is labor-intensive and not easily automated due to the need for precise placement around wiring and other internal components. Guarded hot box tests of multiple LGS test walls with foam and VIP-based exterior insulation systems achieved R-values of up to 31 hr-ft2-°F/Btu. Finally, building energy modeling of multiple modular home designs indicated that the upgraded envelope assemblies can yield heating energy savings of up to 50% and cooling energy savings of up to 30% compared to IECC 2018 standards.

Shrestha, Som [ORNL] (ORCID:0000000183993797)↗