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Wall System Innovation
Vladimir Kochkin Joseph Wiehagen
April 2013
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Wall Innovation Metrics
High R (thermal and air barrier) High Performance Durable, structural
Build‐able
Low transition risk to builders 50% Building America Goal ≈ R25+ (CZ 4 and higher)
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Background
Technologies for high‐R walls have been proposed and used for over 25 years
But real market penetration is very low
Often the last EE measure implemented by builders (e.g. E*)
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Background
High‐R wall solutions have not achieved a broad level of standardization and commonality
A large set of methods and materials entered the market
Multiple and conflicting details Wall characteristics are more critical
= RISK 4
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New Home Starts – Wall Framing
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FRAMING 2001 2006 2011
2x4 @ 16” o.c. 74% 73% 57% 2x4 @ 24” o.c. 2% 3% 4% 2x6 @ 16” o.c. 22% 22% 32% 2x6 @ 24” o.c. 2% 2% 6% Other 1% 0% 1%
TOTAL 100% 100% 100%
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New Home Starts – Wall Sheathing
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FRAMING 2001 2006 2011
None (concrete, SIPs or others) 10% 12% 9% WSP (Plywood, OSB, ZIP) 65% 68% 80% 1/2 inch fiberboard 3% 3% <1% 1/8 inch (Thermoply, EnergyBrace) 3% 2% 3% SIS n/a n/a 1% Foam (XPS, EPS, ISO) 17% 12% 5% Other 3% 4% 0%
TOTAL 100% 100% 100%
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New Home Starts
Oversheathing Oversheathing 2006 2011
Shares of Homes with 2nd Layer of Foam Sheathing 7% 9%
Housewrap 2006Housewrap
Homes with housewrap 54% 2011
75%
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New Home Starts – Cavity Insulation
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FRAMING 2006 2011
Fiberglass batt 76% 68% Fiberglass blown 7% 8% Spray foam 3% 11% Cellulose 11% 8% Other or none 3% 5%
TOTAL 100% 100%
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Increasing Wall Insulation
When builders are asked how would they go about increasing the wall R‐value
About 60% say they would use 2x6 or increase the cavity R‐value
Less than 15% say they would use exterior foam
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Barriers to Adoption
“Devil is in the details”
Claddings Attachments/ connections Windows
Trim Drainage plane
Vapor retarder Air barriers
Framing layout Etc etc etc
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Vision for a Wall Construction Guide
Provide practical (and preferred) solutions for high‐performance walls (1) can be readily implemented in the
field using available methods and materials
(2) can withstand the test of time from environmental and structural loads
(3) grounded in research and testing 11
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Guide Format Builder‐focused and graphics‐rich Application (climate zone) Wall Systems (preferred solutions, not concepts) Details Material characteristics High‐R options Integration
“Hot spots”
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Current High-R Options
Deeper cavity Thermal bridging
limitation
R‐value limit Practical wall
thickness limit
Ext Rigid Insul. OSB behind foam
Cladding attachments
Foam attachment Windows Drainage plane
Panelization
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Is there another way?
Hybrid: Extended Plate & Beam System R25+
Off‐the‐shelf materials Standard cavity (2x4 or 2x6) OSB on the exterior, so is drainage plane
Standard window installation
Integrated rigid foam insulation
Site‐built or panelized
Rim headers integral part of the system
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• • •
Extended Plate & Beam
Plates and studs are different width
R25 (2x4 studs & 2x6 plates) R30 (2x6 studs & 2x8 plates)
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Mock-up Wall
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2-inch Rigid Foam
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Exterior OSB
• Increased nailing at plates to offset weaker nails in the panel field
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Initial Shear Wall Testing
Equivalent to IRC 6”oc nail spacing
Response mode = typical wood wall
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Multi-ply rim header (beam)
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Header built into the floor
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Moisture Performance
WUFI Simulations by Sam Glass (FPL) Baltimore, Chicago, Minneapolis 2x4s&2x6p, 2x6s&2x8p
OSB uncoupled from cavity by foam
OSB MC fluctuates with seasons and depends on cladding but always below 20%
For walls without a vapor retarder, cavity RH higher in very cold climates
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EP&B Summary
Developed for R25+ walls Structural sheathing on the exterior Foam sheathing to exterior of studs Window placement and drainage plane standard methods
Rim header sufficient span most openings Warm Cavity
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EP&B Summary (cont’d)
Same construction methodology for R25 and R30 options
Under development Siding attachment OSB and plate attachment Window and door installation
Rim header: lumber, EWP
Moisture management Additional shear wall testing
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EP&B Summary (cont’d)
Field‐framed or panelized
Standard construction details Durable by design
= Simplified transition from conventional framing options
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