Building emvelopes and thermal mass walls

Building Envelopes and Thermal Mass Walls

Presented by:

Andy TurnerVP Sales and Marketing

Nuform Building Technologies IncLeed AP

Founded in 1992

Royal Building Systems Technologies, LTD

Provides the world with leading edge building systems and technologies

2007-Royal Building SystemsTechnologies became Nuform Building Technologies

New Names-Same Great Products

History of Nuform Building Technologies

Design, Engineering and Specification Assistance

Constructability Assistance

Budgeting Assistance

Sample Assistance

Systems Testing

LEED Analysis

Thermal Analyses

Construction

Comparisons

Introduction

Precast Site Cast

Poured In Place

IntroductionConstruction Comparison

Metal Panel

Conventional

Conform

AIA / CES Program Purpose

This program is registered with the AIA/CES for continuing professional education.

As such, it does not include content deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, 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.

Participants will be able to: Utilize the architectural aspects of

Concrete Wall Panels Understand how to insulate a

concrete wall Understand the benefits of a high

mass wall Understand the benefits of insulated

concrete walls in relation to energy efficiency

Understand overall panel thermal, fire resistance, and moisture ,mold and pest prevention properties

Leed

Learning Objectives

Introduction to Envelopes Benefits of Envelope Construction

Speed of Construction Limited Site Disturbance Energy Efficiency

Moisture Management Wall Physical Performance

R-Values Sustainability Durability

Program Agenda

Introduction Owner Benefits

Benefits to Owners: Speed of Construction Limited Site Disturbance Attractive Appearance Energy Efficiency (R-30+) Increased Daylighting Long Clear Spans 150 MPH + Low Maintenance Sound Transmission (STC 58) Moisture Management Fire Endurance (4-HR)

Facility

Architect CM/Contractor

ScaffoldingUp & Down

CMU Block

Grout & Rebar

Roof

Damproofing

Insulation

Brick

ScaffoldingUp & Down

Cleanup

Conduit

Hand-laid Brick/Block Cavity Wall

Inlaid Brick Architectural Concrete Wall=

Facility

Architect CM/Contractor

Roof

Concrete WallLoad Bearing Panels with Insulation,

Conduit & Brick

Comparative Construction Cycle Analysis

IntroductionLimited Site Disturbance - Panelization

Panelization: Modular Size Repetition

IntroductionLimited Site Disturbance - Panelization

IntroductionLimited Site Disturbance – Panelization

Multiple Textures Add InterestA very economical way to enrich the appearance of your school’s precast exterior is to vary its texture.

Sandblasting

Acid Etching

Retarding (Exposed Aggregate)

Multiple Textures Add InterestA very economical way to enrich the appearance of the facility’s exterior is to vary its texture. Thin Brick and Stone Concrete Sprayed Siding and Hard

Plank Steel PVC

TEXTURE

Introduction Texture Options – Color, Form, and Texture

Introduction Retail

NordstromIrvine, CAIntroduction

Retail

Introduction Retail

IntroductionRetail

IntroductionCorporate & Office

IntroductionHospitality

IntroductionSpiritual

IntroductionEducation

IntroductionMilitary

IntroductionMilitary

IntroductionBarrier Walls

EnergyEfficientHomes

Residential: Dormitories Hotels Health Care Multi-Residence Single-Family

IntroductionHousing

IntroductionHousing

IntroductionControlled Environments

Controlled Environments

IntroductionHealth Care

Cook County Hospital Chicago, ILIntroduction

Health Care

Walls are finished…..

IntroductionEducational – Interior Walls



Minimal maintenance for

20 years or longer . . .• Interior exposed concrete

surface needs only periodic repainting

• Exterior wall surface totally maintenance free, except for caulking every 20 years +/

• If thin brick is used, no need to tuck point concrete mortar joints

=

Insulation IS Important !

Question: Did you know that 7” of load-

bearing structural concrete has approximately the same R-Value as a single panel of glass…R-1.4 !

Types of Concrete Wall PanelsSolid Concrete Wall Panels

Types of Concrete Wall PanelsInsulating Options?

Insulation Position is critical: Interior: Insulation separates you

from the mass effect Exterior: Outside of the bulk mass

of the wall system.

The ability of concrete to store energy and dampen the effect of temperature change on heating and cooling systems is know as the “Thermal Mass Effect.”

Due to the mass effect of insulated precast walls, the performance R-value of the high performance wall system can be two to three times greater than that of the material R-value, resulting in energy cost savings up to or exceeding 50%.

Effective R-ValueThermal Efficiency in a Wall Panel

High Mass Building Conventional Insulated Building

ASHRAE 90.1-1989 Performance Analysis

Material R-Value of R-11

performs as R-25!!Material R-Value of R-11

performs as R-25!!

A P P R O V E D

Calculations will show how what R-Value a Integrally Insulated High Mass Wall Panel will perform at.

ASHRAE 90.1-1989

Building Envelope

Performance Study

Construction

Polypropylene

No Thermal Transfer Molded Plastics No Quality Control

Nylon

Pin Connector:

Pullout Capacity = 1100 lbs.Shear Strength = 500 lbs.

Pullout Capacity = 1100 lbs.Shear Strength = 380 lbs.

Non-Composite Sandwich Wall PanelsConnection Devices

Insignificant Pull Out & Shear Capacity of Connectors

Sandwich Wall PanelsConnection Devices

Composite Sandwich Wall Panels

Thermographic image showing thermal bridging.

Composite Sandwich Wall PanelsThermally Inefficient Connection Devices

Thermo graphic image shows

thermal efficiency:

Edge to Edge Insulation

Conform Energy Efficient Wall PanelsThermally Efficient

Integral InsulationExpanded Polystyrene - EPS – “BEAD BOARD”

Type XI I VIII II IX

Density 0.7 0.9 1.15 1.35 1.8min, pcf

R-Value/inch 3.1 3.6 3.8 4.0 4.2@ 75°F

Compressive strength 5 10 13 15 25min, psi

WVP, max 5 5 3.5 3.5 2perm for 1”

Water Absorption 4 4 3 3 2max., % by vol.

ASTM C578 Standard Specification for Preformed Cellular Polystyrene Thermal Insulation - EPS

Polyisocyanurate:

Closed Cell

Variety of Facers.

R-5.6 to R-6.5

Integral InsulationPolyisocyanurate – POLY ISO

Type Isocast R I IIClass I II Facer triplex aluminum

poly facer Foil Felt or Glass

Fiber Mat

R-Value/inch 6.5 6.5 5.6@ 75°F Compressive strength 25 25 16min, psi WVP, max <.03 <.03 1perm for 1” Water Absorption 0.05 0.05 1.50max, % / vol

ASTM C1289 Standard Specification for Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board

Integral InsulationPolyisocyanurate – POLY ISO

Integral InsulationExtruded Polystyrene – XPS

Extruded Polystyrene: Closed cell structure. Integral high density skin and core. Typical R-values of R5.0 to R5.6 per inch.

Magnified Cross Section

Insulation

ASTM C578 Standard Specification for Preformed Cellular Polystyrene Thermal Insulation - XPSTYPE X IV VI VII V

Density, min., pcf

1.35 1.60 1.80 2.20 3.00

R-Value/inch @ 75F

5.00 5.00 5.00 5.00 5.00

Compressive Strength, min., psi

15 25 40 60 100

WVP, max., perm for 1.5”

0.55 0.55 0.55 0.55 0.55

Water Absorption, max., % by vol.

0.3 0.3 0.3 0.3 0.3

Moisture Migration

Bottom Line: No Moisture Means No Mold or Mildew

Insulated Concrete Sandwich WallsMoisture Management

The problems associated with moisture and its affects on building components are well known, and costly to repair.

Most Insurers have stopped coveragefor these incidents leaving ownersno other avenue for compensation but the court system.

Bottom Line: No Moisture Means No Mold or Mildew

In general, molds demand a favorable combination of the following conditions to germinate, sporulate, and grow: Fungal spores settling on the surface Oxygen availability Optimal temperatures between 40-70 degrees F Nutrient availability (wood, paper, cellulose based materials) Moisture (liquid or relative humidity above 70%)

The first four conditions are met in almost every building. The key remaining factor is moisture, which may be controlled

by adhering to sound construction practices discussed in this presentation.

Insulated Concrete Sandwich WallsMoisture Management

Diffusion from the exterior side of the wall is also common.

In spring, summer, and fall, wind driven rain can be absorbed in the exterior concrete and stored.

Insulation is critical in preventing this moisture vapor drive:

In a Hot/Mixed Climate:

Concrete can’t Exterior Paints can’t

Insulated Concrete Sandwich WallsMoisture Vapor Drive

Warm Outside

Cold Inside

After the rain, as the sun heats up the concrete wythe, the moisture turns to vapor and is driven through the wall

Moisture will always diffuse, especially if the perm rating is greater than 1.0

Outside-In Vapor Drive

Insulation will enhance the efficiency of the entire wall system.

PVC Encompassed Insulation and Concrete form

Moisture Vapor Drive

Cold Inside Air

Outside-In Vapor Drive

Exfiltration

Insulated Concrete Sandwich WallsMoisture Vapor Drive

What Is Vapor Diffusion? The Process by which water vapor migrates through a wall

system and it’s components such as gypsum, concrete, insulation and paint.

Each components of the wall system has a perm rating The International Building Code says that a material with a

perm rating of 1.0 or less is a vapor retarder.

Examples of the average perm rating for different wall components… Gypsum 12 - 50 perms Plastic Sheet Barriers (2-10 mil) .16 – .03 perms Rigid Insulation 5.8 – .03 perms Concrete 3.2 perms PVC 0 perms


Photograph showing thermal bridging

and moisture migration.

Removing wallpaper, mold and mildew is prevalent throughout the entire wall.


Cost of Energy

The cost of energy continues to escalate. Energy efficiency is of growing concern.

36% of ALL energy consumed in the U.S. is consumed by buildings

Natural gas prices are expected to increase from 30% to 70% compared to one year ago

“Energy efficient building shell is one that integrates and optimizes insulation levels, glazing, shading, thermal mass, air leakage control, and light-colored exterior surfaces”

(Sustainable Building Industry Council - High Performance School Buildings 2005 Second Edition)

Energy Efficiency

Effective R-value = R-value x Correction Factor

ASHRAE 90.1 recognizes thermal short circuits and applies a correction factor to account for the higher heat loss through highly conductive steel studs.

Effective R-ValueThermal Loss Through Wall Panel

INTERIOR AIR FILM

GYPSUM BOARD

STEEL STUD R-19 BATT INSULATION

EXTERIOR GYPSUM

AIR SPACE

MASONRY

EXTERIOR AIR FILM

The ASHRAE “PARALLEL PATH METHOD” was used to calculate the effective thermal performance for the metal frame wall construction. The correction factors from ASHRAE Standard 90.1, 1989 User’s Manual were used to assign reduced thermal resistance values for the insulated stud cavity.

ComponentInt air filmGypsumVapor retarderR19 batt GypsumAir spaceBrickExt.air filmWall Effective R-Value:

ComponentInt air filmGypsumVapor retarderR19 batt GypsumAir spaceBrickExt.air filmWall Effective R-Value:

R-value0.680.450.018.600.450.600.800.1711.76

R-value0.680.450.018.600.450.600.800.1711.76

Let’s look at the assembly of the Steel Stud / Brick Wall:

6” 20 GA S.S. @ 24” o.c., R-19 Batt + ½” Gyp.

Effective R-ValueWhat R-Value are you Purchasing?

Effective R-ValueThermal Loss Through Wall Panels

Solid Concrete Zones Metal Thermal Bridges Thermal Short Circuits

The thermal

conductivity of steel

& solid concrete

sections account for

significant thermal

losses!

Up to 60% thermal loss !!


Panel Description Material R-Value1

Test R-Value

Percent Loss

Panel with Only Steel Ties

10.48 7.55 -27.96%

Panel with Only Solid Concrete

10.48 5.77 -44.94%

Panel with Solid Concrete & Steel Ties

10.48 4.55 -56.58%

1. Value obtained summing R-values for concrete & insulation layers, no air films included.Note: All 3-2-3 panels made with extruded polystyrene.

Source: “Summary of Thermal Tests of Insulated Concrete Sandwich Walls U.S.Dept. of Energy 1998-1999.” Composite Technologies Corp., IA, 1999.


Measurements of thermal loss in sandwich panels:

Panel Description Material R-Value1

Test R-Value

Percent Loss

Panel with only steel ties 10.48 7.55 27.96%

Panel with only solid concrete

10.48 5.77 44.94%

Panel with solid concrete & steel ties

10.48 4.55 56.58%

Conform Wall Panel 10.48 10.57 -0.86%

Measurements of thermal loss in sandwich panels:

Effective R-ValueThermal Efficiency in a Wall Panel

1. Value obtained summing R-values for concrete & insulation layers, no air films included.Note: All 3-2-3 panels made with extruded polystyrene.

Source: “Summary of Thermal Tests of Insulated Concrete Sandwich Walls U.S.Dept. of Energy 1998-1999.” Composite Technologies Corp., IA, 1999.

Thermographic image showing thermal bridging.


This school is constructed with conventional brick / masonry construction.

It took 8½ months to construct.

This school is actually 4,000 sq.ft. larger but was constructed with an integrally insulated sandwich wall

panel. Construction time was only 5½ months!

School Comparison Electrical Cost Natural Gas Cost

Traditional School $118.89 per day $100.78 per day

High Mass Wall $91.02 per day $65.95 per day

Percent Savings 31% 52%

Thermal Efficiency Energy Savings

United Nations Brundtland Commission Report (1987): Defined sustainable development and urged the world to take note…

“Sustainable development is that which meets the needs of the present without compromising the ability of future generations to

meet their own needs.”

This Concern Gave Birth to:

The U.S. Green Building Council (USGBC)Initiated

the LEED SystemA nationally accepted standard for developing green buildings

The LEED system currently addresses six (6) areas of construction. Projects opting to qualify for LEED Certification are graded in those 6 different categories and must accumulate at least 26 points.

Insulated Concrete Sandwich WallsSustainable Design – LEED TM

Credit Category Points AvailableSustainable Sites 14

Water Efficiency 5

Energy and Atmosphere 17

Materials and Resources 13

Indoor Environmental Quality 15

Total Core Points 64Innovation and Design Process 5

LEED Certification LevelsCertified 26-32 Pts

Silver 33-38 Pts

Gold 39-51 Pts

Platinum 52-69 Pts

Within each of the 6 credit categories are severalsub-categories that create the path for scoring points


Sustainable Sites Points

Credit 5.1 Site Development, Protect or Restore Habitat 1Credit 5.2 Site Development, Maximize Open Space 1Credit 7.1 Heat Island Effect, Non-Roof 0

Energy & AtmospherePrereq 2 Minimum Energy Performance RequiredCredit 1 Optimize Energy Performance 15% to 60% 2

Materials & ResourcesPrereq 1 Storage and Collection of Recyclables Required Credit 1.1 Building Reuse, Maintain 75% of Existing Walls, Floors & Roof 0Credit 1.2 Building Reuse, Maintain 95% of Existing Walls, Floors & Roof 0Credit 2.1 Construction Waste Management, Divert 50% from Disposal 1Credit 2.2 Construction Waste Management, Divert 75% From Disposal 1Credit 4.1 Recycled Content, Use 10% (Post-Consumer + Half Pre-Consumer) 1Credit 4.2 Recycled Content, Use 20% (Post-Consumer + Half Pre-Consumer) 1Credit 5.1 Regional Materials, 10% Extracted, Processed and Manufactured Regionally 1Credit 5.2 Regional Materials, 20% Extracted, Processed and Manufactured Regionally 1

Indoor Environmental QualityCredit 3.1 Construction IAQ Management Plan, During Construction 1

Innovation & Design ProcessCredit 1.1 Innovation in Design, Use of High Volume

supplementary Cementitious Materials. 1Credit 1.2-1.4 Apply for other credits demonstrating exceptional performance 2Credit 2.1 LEEDTM Accredited Professional 1

LEED Silver


Insulated Concrete Sandwich WallsSummary

Benefits to Owners: Speed of Construction Limited Site Disturbance Attractive Appearance Energy Efficiency (R-30+) Increased Daylighting Long Clear Spans 150 MPH + Low Maintenance Sound Transmission (STC 58) Moisture Management Fire Endurance (4-HR) Seismic D Rated

American Institute of ArchitectContinuing Education Systems.

This concludes the CES portion of the program. Credit earned during this program

will be reported to CES Records for AIA members. Certificate of Completion for non-

AIA members is available on request.

Insulated Concrete Sandwich WallsAIA / CES Program Purpose

The NUFORM Building SystemSpecifying or Designing NUFORM?

Think of NUFORM: Fully Tested & Warranted Complete Detail Database In-House AEC Support Valuable Team Member Complete specs, details, tech data,

video, samples and testing available World Wide Experience Over 100 Million Wall SF Installed www.nuformdirect.com