DEEP ENERGY RETROFITS: FROM DESIGN TO DATA COLLECTION AND ANALYSIS

AIA Pittsburgh Provider Number

Deep Energy Retrofits: From Design to Data Collection and AnalysisDER_BP15

Anastasia Herk / Rich Baker / Andrew Poerschke4.23.15

Credit(s) earned on completion of this course will be reported to AIA CES for AIA members. Certificates of Completion for both AIA members and non-AIA members are available upon request.

This course is registered with AIA CES

for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner ofhandling, using, distributing, or dealing in any material or product._______________________________________

____

Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without written

permission of the speaker is prohibited.

© IBACOS 2012

Copyright Materials

The presenters will walk through a case study of a deep energy retrofit installed on nine homes in the Syracuse, New York, area. This case study will include a review of the client’s (NYSERDA) project goals as well as IBACOS’s plan to meet those goals. The presenters will compare and contrast two different approaches to deep energy retrofit design: rigid foam and spray foam insulation. They will evaluate the relationship between structure, HVAC systems, and building envelope design. Lastly, they will discuss lessons learned from design to installation, including a cost-benefit analysis.

CourseDescription

LearningObjectives

1. Understand the definition of a “Deep Energy Retrofit”, and specifically what it meant for the

case study client.

2. Compare and contrast two different approaches to deep energy retrofit design: rigid foam and spray foam insulation.

3. Understand the relationship between structure, HVAC systems, and building envelope design, and how these variables can be manipulated.

4. Assess and apply the case study lessons, including analysis of data and cost, to one’s own work.

At the end of the this course, participants will be able to:

Exterior Insulation

Strategies for Deep Energy

Retrofits

Anastasia Herk

Rich Baker

Andrew Poerschke

Integrated Systems Researchwe collaborate with the industry on the next generation of

homes and housing systems

• Integrated Systems Research

• Market & Product Development

• Industry Network

• Builder Enablement

• International Development

For almost 25 years, we have partnered with

a network of leading homebuilders,

manufacturers, government and industry

groups to improve building quality and

performance in the United States.

Research project funded by the New York State Energy Research

& Development Authority (NYSERDA).

GOAL: to explore the benefits and costs of completing deep

energy retrofit projects on New York State homes.

The Deep Energy Retrofit Project

What is a Deep Energy Retrofit: (as described by NYSERDA)

A practice that goes well above and beyond the current common practice

of performing energy efficiency work. This involves the following:

- substantially improving the exterior building envelop with aggressive,

emerging insulating practices

- installing new or relocating existing windows

- sealing the below grade foundation to the wall connections

- sealing the roof to the wall connection with insulation that also provides

an air barrier

Typical mechanical systems are then significantly downsized and

performance results yield a reduction in whole building energy load of at

least 50% .

Goals of Research Project: • Evaluate cost and performance trade offs between:

– Spray-foam exterior walls

– Foamboard exterior walls

– Home Performance with Energy Star Home (HPwES) on steroids• No significant modification of exterior walls

• No HVAC upgrades / no window upgrades

• 50% peak load and annual heating load reduction

• R-30Target for Center of Wall

• .25 CFM50 per shell SF

• $10/sf insulation strategies

• 20% minimum contribution from homeowners

Project Partners

Manufacturers, Contractors, NYSERDA, Engineers

11

Assumptions about the Homeowner:

• Homeowner has an older house so they were already

going to re-side, which in turn could mean potential for

other energy upgrade opportunities:

– HVAC

– Air sealing

– Windows

– Insulation

– Water heating

Why do this?

• Why cover existing siding? :

– Minimize need for disturbing existing

construction that includes lead paint

– Allows for re-skinning building without having to

remove existing siding

• Why use closed cell spray foam?:

– Spray foam is an integral insulation, air sealing

and draining plane material in one application

– No taping and flashing like you would with rigid

foam

• Why use rigid foam?:

– Familiarity for the contractor – readily accessible

and easy to work with

– Lower cost per square foot – valuable

comparison to spray foam

Project Homes Overview

Test House Insulation Type Building America House

House 1 Spray

House 2 Rigid

House 3 Rigid

House 4 Rigid BA House 1

House 5 Home Performance with Energy Star

BA House 3

House 6 Rigid

House 7 Spray BA House 2

House 8Spray

House 9 Spray

• Building America : The U.S. Department of Energy's (DOE) Building America program

has been a source of innovations in residential building energy performance, durability,

quality, affordability, and comfort for 20 years. This world-class research program

partners with industry (including many of the top U.S. home builders) to bring cutting-

edge innovations and resources to market.

Initial concept

Brainstorming Ideas: Bottom of Wall

First House Construction Detail: Bottom of Wall

Brainstorming Ideas: Top of Wall

First House Construction Detail : Top of Wall

Sketchup Ideas

Wall Details –Bottom of Wall: Foam Board

Existing Wall

2 layers of ½” Foamboard

Spray-foam

2” Foamboard

Double 2 x 6 Ledger

Wall Details –Top of Wall :Foam Board

Spray-foam

New 2 x 6 Ledger

Existing Wall

3” Foamboard

New Siding

Foam Board

• 2-Story

• Rim/band

Joist Detail

• Rim/band

Joist

Attachment

• Door Frame

Detail

• Electrical

Detail

Mockups: Door/ Electrical/ 1st-2nd Floor

• New Wall to Roof Detail

• Window Installation Detail

• Top of New Wall Detail

• Exterior Corner Detail

• Electrical Detail

Mockups: Window Details/ Top of Wall

• Insulation of

Foundation

Walls

• Rim/band Joist

Detail

• Rim/band Joist

Attachment

Detail

• Bottom of New

Wall Detail

Mockups: Foundation

• New Wall to

Roof Detail

• Overhang

Build-out

Detail

• Top of New

Wall Detail

• Exterior

Corner Detail

Mockups: Roof-to-Wall

Wall Mockup 1

Wall Mockup 2

Wall Mockup 3

Wall Mockup 4

Spray Foam Experiment

Test House: Spray Foam Application7th home built : Building America 2nd home

New wall framing: siding remained1st home built: non - Building America

New wall framing: siding removed7th home built : Building America 2nd home

Installation of Spray Foam

New Wall with Insulation

New Wall Intersection at Roof

Installation of Thin Profile Structural

Sheathing and New Siding

Test Houses: Final

7th home built : Building America 2nd home

1st home built: non - Building America

Installation of Ledger Boards

Brackets and Spray Foam

Extending timing with construction

Permitting process

Order of installation

The challenge of staging construction for testing

Integrating utility logistics

Spray Foam Application : Lessons Learned

Step 1 Step 2 Step 3

Step-by-step Installation Process


Note: Some siding profiles may require thin profile structural sheathing


Test House: Rigid Foam Application

This home had 2

layers of 1 ½”

Styrofoam installed

over the existing

sheathing with 2x4’s

installed on face

every 16” on center

on 3 out of 4

facades.

4th home built: Building America 1st home

Rigid Foam Application: Fire Wall

The façade closest

to the neighboring

house needed a fire

rated wall

assembly.

Existing siding was

removed.

5/8” type X drywall

was installed.

Rigid Foam Application: Fire Wall

House wrap was applied and then the

normal rigid foam application was

installed.

Window openings were

wrapped in Tyvek prior to

window insulation

DuPont Flex Wrap was installed under the windows to eliminate water intrusion

Window Application

Ready for Siding Application

Test House: Rigid Foam Application Final

The attic was spray-foamed

replacing insulation that was

missing and non-existent air

sealing

Test House: Attic Insulation 3rd home built: non - Building America

The attic was then finished to

be a new office area for the

customer

Attic Insulation

As part of the

project, this chimney

was removed

Chimney Removal

Chimney Removal

Air Leakage Reduction

Air Sealing Improvements1st home built: non - Building America

House 4: Rigid

Parameters Test House 4:

Rigid

Test House 7:

Spray

Test House 5:

HPwES

Square Feet of Conditioned Space 1,682 ft2 972 ft2 1,676 ft2

Perimeter of House 100 ft 124 ft 154 ft

DER insulated Wall Height 18 ft 10 ft 18 ft*

Shell Square Footage (ssf) 1,800 ssf 1,240 ssf 2,772 ssf

*average height due to roof slopes

Building America Test Home Comparison

House 7: Spray House 5: HPwES

1st home built: non - Building America

Pre- and Post- DER Info: BA Houses

House DER

Wall Insulation Attic Insulation

Type R-Value/ Thickness Type R-Value/

Thickness

House 4: Rigid

Pre- Fiberglass R-11 Fiberglass batt R-11*/3 in.

Post- XPS rigid foam R-23/2.5 in.

Closed-cell foam and dense-pack

cellulose into slants; blown-in cellulose on flat

R-54

House 5. HPwES

Pre- – – Fiberglass R-28*/10 in.

Post-

Dense-pack fiberglass in wall R-16/4 in. Fiberglass R-50

House 7. Spray

Pre- Urea-formaldehyde foam R-13* Fiberglass R-2*/0–6 in.

Post- Closed-cell foam R-30/2.5 in. Blown fiberglass R-50

*R-value estimated by IBACOS using insulation thicknesses or notes provided by the contractor.

Specifications Pre-Upgrade

Conditions

DER Upgrade

Package

Foundation Wall Insulation Uninsulated 19.8

Above-Grade Exterior Wall

Insulation R-Value3.9 15.3

Rim/Band/Box Sill Insulation Uninsulated Spray Foam

Attic Insulation R-Value 22.7 29.9

Window U-Value/SHGC 0.49/0.56 0.2/0.23

Duct Location Unfinished Basement Finished Basement

Heating Gas, 80% AFUE Gas, 95% AFUE

Air Conditioning Single Stage, SEER 8 Single Stage, SEER 14.5

HVAC Equipment Location Unfinished Basement Unfinished Basement

Whole-House Ventilation Strategy Exhaust Exhaust

Water Heater Type/EF Gas Standard Gas Premium

Pre-Retrofit Btuh Post-Retrofit Btuh % Reduction from Pre- to

Post-Retrofit

Heat Cool Heat Cool Heat Cool

Totals 82,402 32,587 32,123 12,275 61% 62%

Installed Capacity 60,000 30,000

*NOTE: No Duct Sealing was done as a part of these DER installations

Test House 4: Rigid

Test House 4: Rigid


Conditions

DER Upgrade

Package

Foundation Wall Insulation Uninsulated Uninsulated

Above-Grade Exterior Wall

Insulation R-Value10 21.9

Rim/Band/Box Sill Insulation Uninsulated Spray Foam

Attic Insulation R-Value 4 52.5


Duct Location Unfinished Basement Unfinished Basement


Air Conditioning None Single Stage, SEER 13

HVAC Equipment Location Unfinished Basement Unfinished Basement



Pre-Retrofit Btuh Post-Retrofit Btuh % Reduction from

Pre- to Post-Retrofit


Totals 56,172 24,400 22,591 8,739 60% 64%Installed Capacity 40,000 24,000


Test House 7: Spray

Test House 7: Spray


Conditions

DER Upgrade

Package

Foundation Wall Insulation Uninsulated 20.1

Above-Grade Exterior Wall Insulation

R-Value3.6 12.6

Rim/Band/Box Sill Insulation Uninsulated Uninsulated

Attic Insulation R-Value 14.5 71


Duct Location In Conditioned Space In Conditioned Space


Air Conditioning Single Stage, SEER 8 Single Stage, SEER 13

HVAC Equipment Location Basement Basement



Pre-Retrofit Btuh Post-Retrofit Btuh % Reduction from Pre-

to Post-Retrofit


Totals 97,560 42,184 50,490 18,698 48% 56%Installed Capacity 80,000 36,000


Test House 5: HPwES

Test House 7: Spray

Test Home Air leakage Results

Test House 4:

Rigid

Test House 7:

Spray

Test House 5:

HPwES

Units

Performance

Metric

Pre-

Retrofit

Post-

Retrofit

Pre-

Retrofit

Post-

Retrofit

Pre-

Retrofit

Post-

Retrofit

House Size 2,254 1,908 2,316 Square

Feet of

Finished

Floor Area

House

Volume

18,720 15,552 16,865 Cubic Feet

Final Whole-

House Air

Leakage

9.1 4.74

(47%)

6.9 4.08

(41%)

14.8 11.4

(23%)

ACH50

%

Reduction

Monitoring Equipment

Room by Room Variability

ACCA RS - Every room should be 2°F from T-stat in heating and 3°F in cooling

4th home built: 1st Building America Home - Rigid

Room by Room Variability7th home built: 2nd Building America Home - Spray

Room by Room Variability5th home built: 3rd Building America Home – HPwES

So…..

Which is better?

Rigid or Spray foam?

Initial Costing: First build house

Actual Wall Costing

Test House

Identification

Cost per SSF ($)

Without Siding With Siding

House 1: Spray $10.76 $19.26

House 2: Rigid $11.02 $19.22

House 3: Rigid $13.85 $20.82

House 4: Rigid $10.39 $18.64

House 5: HPwES $13.22* NA**

House 6: Rigid $12.68 $25.57

House 7: Spray $11.87 $21.66

House 8: Spray $11.32 $19.65

House 9: Spray $13.25 $26.38

*This home did not receive siding so the cost per SSF does not include removal of existing siding or new siding

Actual DER Overall Costing

Test HouseTotal

Project Cost

NYSERDA DER Fund

Cost to Homeowner

NYSERDA Material Donation

NYSERDA HEMI*

GJGNY Loan**

Home Head

Quarters Loan***

House 1: Spray $75,990 $37,500 $38,490 – – – –

House 2: Rigid $52,302 $35,000 $17,302 – – – –

House 3: Rigid $84,188 $49,000 $35,188 – $2,000 $25,000 $8,188

House 4: Rigid $73,992 $10,000 $49,692 – – $14,300 –

House 5: HPwES $35,954 $15,000 $20,954 $2,020 $1,950 – –

House 6: Rigid $109,319 $35,000 $74,319 – $700 – –

House 7: Spray $58,662 $32,000 $26,662 – $1,250 $13,000 $12,412

House 8: Spray $59,776 $32,000 $27,776 – $1,250 $13,000 $13,526

House 9: Spray $75,843 $40,000 $35,843 – – – –

* HEMI: High Efficiency Measure Incentive.** GJGNY: Green Jobs Green New York; 3.49% 15-year fixed rate.*** 3.99% 10-year fixed secured loan.

House 4: Rigid

What does $73,992* get you?

Rigid foam exterior insulation

New 95% AFUE 60k BTU Gas Furnace

New 14.5 SEER 30k BTU Air Conditioner

New ERV installed 40gal

DHW Power Vented

CFL light bulbs

Attic air sealing and insulation in crawl space

Basement Rim Joist spray foam

18 new windows: Okna Insul-tec 500 series (Triple glaze .20 u-value)

New siding

*Including NYSERDA money and Loan money

House 7: Spray


Spray foam exterior insulation


New 13 SEER 24k BTU Air Conditioner

New electric programmable thermostat

New ERV installed DHW Power Vented 40 gal gas

CFL light bulbs

Attic air sealing and open blown fiberglass insulation

Basement: Rim Joist spray foam, install 3 glass block windows

8 new windows: Okna Insul-tec 500 series (Triple glaze .20 u-value)

New siding with t-ply underlayment

Redirect 1 bath fan to roof


House 5: HPwES


Drill and Fill dense pack exterior wall insulation


New 13 SEER 24k BTU Air Conditioner

New ductwork as needed, add 3 new supply runs to sunroom

New electric 2 stage programmable thermostat

DHW Power Vented 40 gal gas

Attic air sealing and mixture of open blown / dense pack insulation

Basement: Rim Joist spray foam, install 4 glass block windows

Crawlspace : 2” spray closed cell foam to interior foundation walls

6 new windows: Okna Insul-tec 500 series (Triple glaze .20 u-

value)


This concludes The American Institute of Architects Continuing Education Systems Course

Rich Baker Manager, Builder Solutions

[email protected]

Andrew PoerschkeSpecialist, Energy Engineering

[email protected]

Anastasia Herk Project Manager

[email protected]

mailto:[email protected]



DEEP ENERGY RETROFITS: FROM DESIGN TO DATA COLLECTION AND ANALYSIS

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