U.S. patent application number 15/208033 was filed with the patent office on 2017-02-02 for system and method for panelized, superinsulated building envelopes.
The applicant listed for this patent is Christian Peter CORSON. Invention is credited to Christian Peter CORSON.
Application Number | 20170030072 15/208033 |
Document ID | / |
Family ID | 57883359 |
Filed Date | 2017-02-02 |
United States Patent
Application |
20170030072 |
Kind Code |
A1 |
CORSON; Christian Peter |
February 2, 2017 |
SYSTEM AND METHOD FOR PANELIZED, SUPERINSULATED BUILDING
ENVELOPES
Abstract
Panelized wall and roof structures for constructing energy
efficient buildings. The panelized structures have a structural
layer with insulation, an airtight layer providing a primary air
barrier and a vapor retarder exterior to the structural layer, a
vapor open blanket layer including insulation and attached to the
structural layer via structural screws, a weather resistant barrier
provided exterior to the blanket layer and including an airtight,
water-repelling, vapor-open fabric, and a rain screen provided
exterior to the weather resistant barrier and including a drainage
plane for channeling moisture away from the weather resistant
barrier.
Inventors: |
CORSON; Christian Peter;
(Northport, ME) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CORSON; Christian Peter |
Northport |
ME |
US |
|
|
Family ID: |
57883359 |
Appl. No.: |
15/208033 |
Filed: |
July 12, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62197931 |
Jul 28, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 7/04 20130101; E04D
13/1625 20130101; E04B 2001/7679 20130101; E04B 1/0007 20130101;
E04B 1/7675 20130101; E04B 5/12 20130101; E04D 13/1612 20130101;
E04D 13/1618 20130101; E04B 2/707 20130101 |
International
Class: |
E04B 1/66 20060101
E04B001/66; E04B 1/70 20060101 E04B001/70; E04D 13/17 20060101
E04D013/17; E04C 2/52 20060101 E04C002/52; E04D 13/04 20060101
E04D013/04 |
Claims
1. A system for constructing an energy efficient building, said
system comprising: at least one panelized structure having a
structural layer including a first set of voids and located at an
inner area of said at least one panelized structure, said inner
area being adjacent to intended living space of said energy
efficient building, an airtight layer formed by a first sheathing
layer providing a primary air barrier and a vapor retarder exterior
to said structural layer, a blanket layer located exterior to said
first sheathing layer and formed by a plurality of vertical members
with a second set of voids located between each of said vertical
members, a weather resistant barrier located exterior to said
blanket layer and including a second sheathing layer formed by an
airtight, water-repelling, vapor-open fabric, a rain screen located
exterior to said weather resistant barrier, said rain screen being
adjacent to outdoor space external to said energy efficient
building and including a drainage plane internal thereto, said
drainage plane for channeling moisture away from said weather
resistant barrier; insulation for placement within said structural
layer and said blanket layer; and wherein said at least one
panelized structure is air-sealed and insulated within said first
and second sets of voids after installation.
2. The system as claimed in claim 1 wherein at least a first
panelized structure and a second panelized structure are provided
and include a marriage joint therebetween, said marriage joint
configured to provide continuity of said first sheathing layer
between said first panelized structure and said second panelized
structure and continuity of said second sheathing layer between
said first panelized structure and said second panelized
structure.
3. The system as claimed in claim 2 wherein said first panelized
structure is a wall panel and said second panelized structure is a
roof panel.
4. The system as claimed in claim 3 wherein said second panelized
structure forms a pitched roof of said energy efficient
building.
5. The system as claimed in claim 3 wherein said second panelized
structure forms a flat roof of said energy efficient building.
6. The system as claimed in claim 2 wherein said first panelized
structure and said second panelized structure are both wall
panels.
7. The system as claimed in claim 6 wherein said wall panels form a
contiguous straight section of wall.
8. The system as claimed in claim 6 wherein said wall panels are
arranged at a right angle to one another and form an interior
corner section of wall.
9. The system as claimed in claim 6 wherein said wall panels are
arranged at a right angle to one another and form an exterior
corner section of wall.
10. The system as claimed in claim 2 wherein said blanket layer is
attached to said structural layer via structural screws.
11. The system as claimed in claim 10 wherein said airtight layer
is retained in place between said blanket layer and said structural
layer via said structural screws.
12. A panelized wall structure for constructing an energy efficient
building, said panelized wall structure comprising: a structural
layer having a first set of voids and located at an inner area of
said panelized wall structure, said inner area being adjacent to
intended living space of said energy efficient building; an
airtight layer formed by a first sheathing layer providing a
primary air barrier and a vapor retarder exterior to said
structural layer; a blanket layer located exterior to said first
sheathing layer and formed by a plurality of vertical members with
a second set of voids located between each of said vertical
members; a weather resistant barrier located exterior to said
blanket layer and including a second sheathing layer formed by an
airtight, water-repelling, vapor-open fabric; and a rain screen
located exterior to said weather resistant barrier, said rain
screen being adjacent to outdoor space external to said energy
efficient building and including a drainage plane internal thereto,
said drainage plane for channeling moisture away from said weather
resistant barrier.
13. The panelized wall structure as claimed in claim 12 further
including insulation located within said first and second set of
voids.
14. The panelized wall structure as claimed in claim 13 further
including a marriage joint configured to provide continuity of said
first sheathing layer between said panelized wall structure and
another first sheathing layer of another panelized wall structure
and continuity of said second sheathing layer between said
panelized wall structure and another second sheathing layer of
another panelized wall structure.
15. The panelized wall structure as claimed in claim 13 wherein
said blanket layer is attached to said structural layer via
structural screws.
16. The panelized wall structure as claimed in claim 13 wherein
said airtight layer is retained in place between said blanket layer
and said structural layer via said structural screws.
17. A panelized roof structure for constructing an energy efficient
building, said panelized roof structure for constructing an energy
efficient building, said panelized roof structure comprising: a
structural layer having a first set of voids and located at an
inner area of said panelized roof structure, said inner area being
adjacent to intended living space of said energy efficient
building; an airtight layer formed by a first sheathing layer
providing a primary air barrier and a vapor retarder exterior to
said structural layer; a blanket layer located exterior to said
first sheathing layer and formed by a plurality of vertical members
with a second set of voids located between each of said vertical
members; a weather resistant barrier located exterior to said
blanket layer and including a second sheathing layer formed by an
airtight, water-repelling, vapor-open fabric; and a rain screen
located exterior to said weather resistant barrier, said rain
screen being adjacent to outdoor space external to said energy
efficient building and including a drainage plane internal thereto,
said drainage plane for channeling moisture away from said weather
resistant barrier.
18. The panelized roof structure as claimed in claim 17 further
including insulation located within said first and second set of
voids.
19. The panelized roof structure as claimed in claim 18 further
including a marriage joint configured to provide continuity of said
first sheathing layer between said panelized roof structure and a
corresponding first sheathing layer of a panelized wall structure
and continuity of said second sheathing layer between said
panelized roof structure and a corresponding second sheathing layer
of a panelized wall structure.
20. The panelized roof structure as claimed in claim 18 wherein
said blanket layer is attached to said structural layer via
structural screws, and said airtight layer is retained in place
between said blanket layer and said structural layer via said
structural screws.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims priority to U.S. Provisional
Application Ser. No. 62/197,931 filed on 28 Jul. 2015 and herein
incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of construction
of energy efficient buildings. Moreover, the present invention
relates to panelized, superinsulated building systems and
methods.
BACKGROUND OF THE INVENTION
[0003] In the design and construction of buildings, it is well
known that energy efficiency and building insulation go hand in
hand. Accordingly, numerous types of insulation systems and methods
exist. Within typical "stick built" construction using framed
lumber, voids are created within walls. In such exterior walls,
these voids are often filled with fiberglass, cellulose-based, or
foam material which have varied insulative value. Vapor barriers
are typically added to such exterior walls in order to enhance the
insulative effect. However, due to the nature of such framed
lumber, thermal bridging often detrimentally occurs to facilitate
heat transfer within walls. As well, a variety of leakage points
exist due to difficulties inherent to current vapor barrier
technology.
[0004] Improvements have been attempted in the form of structural
insulated panels (SIPs) which are a high performance building
system for residential and light commercial construction. The
panels consist of an insulating foam core (e.g., extruded
polystyrene XPS or expanded polystyrene EPS foam) sandwiched
between two structural facings, typically oriented strand board
(OSB). SIPs are manufactured under factory controlled conditions
and can be fabricated to fit nearly any building design. The result
is a building system that is extremely strong, energy efficient and
cost effective. Disadvantageously however, standard SIP technology
typically requires spline joints which connect the panels together
while allowing thermal bridging to occur.
[0005] In order for more new construction to be energy efficient
and durable against the moisture-related problems that are
sometimes associated with thick, airtight assemblies, new
construction methods are required. The assemblies that will perform
best from energy and resiliency viewpoints are inherently complex,
time-consuming to assemble, and require specialized training to
execute effectively.
[0006] It would be advantageous to obviate or mitigate these
disadvantages such that heat transfer between building interiors
and exteriors, thermal bridging, and leakage are substantially
reduced or eliminated.
SUMMARY OF THE INVENTION
[0007] The present invention provides a system and method for
panelized, superinsulated building envelopes that reduces or
substantially eliminates many problems in building construction
including heat transfer between building interiors and exteriors,
thermal bridging, and leakage. The present invention reduces
contributions to climate change due to wasted energy in the built
environment. Difficulties in quality control for and time required
on site to build complicated building envelope assemblies are
minimized by way of the present invention.
[0008] The present invention reduces moisture-related issues,
including reducing problems from mold inside building envelopes
that are not vapor-open to the exterior and improving cladding
longevity in building assemblies without a rain screen detail. The
present invention also reduces moisture-related problems, including
mold, in building assemblies insulated to higher levels than
required by building codes.
[0009] The present invention provides effective air-sealing of
building assembly panels, maintains integrity of the air barrier
during and after the construction process, and provides enhanced
insulating of "marriage joints" between building assembly
panels.
[0010] The present invention overcomes difficulties in providing
continuity of a weather resistant barrier between building assembly
panels and resolves both problems related to vapor open
construction of exterior and interior corners and also difficulties
in building exterior and interior corners without thermal
bridges.
[0011] The present invention also provides connections from wall to
roof and at window and door supports that are free of thermal
bridging.
[0012] The present invention enables a window assembly allowing for
drainage into the rain screen, behind the cladding.
[0013] The present invention provides a service cavity on the
inside of a building envelope assembly.
[0014] The present invention also provides effective insulation and
air sealing of bother concrete slab foundations as well as
foam-free pier foundations.
[0015] The present invention provides these benefits and solves
these problems by using specific assemblies constructed in a
controlled shop environment by skilled workers, then assembled on
site using prescribed details. Anyone building a new home, new
commercial or institutional building, or building significant
additions to existing structures may benefit from the present
system and method. Because most of the cost is in building and
installing the panels, with travel costs as a comparatively minor
expense, the system and method of the present invention effectively
enables building houses in any location so as to bring low-energy,
high-performance buildings to anyone constructing a building.
[0016] According to a first aspect of the invention there is
provided a system for constructing an energy efficient building,
the system includes: at least one panelized structure having a
structural layer including a first set of voids and located at an
inner area of the at least one panelized structure, the inner area
being adjacent to intended living space of the energy efficient
building, an airtight layer formed by a first sheathing layer
providing a primary air barrier and a vapor retarder exterior to
the structural layer, a blanket layer located exterior to the first
sheathing layer and formed by a plurality of vertical members with
a second set of voids located between each of the vertical members,
a weather resistant barrier located exterior to the blanket layer
and including a second sheathing layer formed by an airtight,
water-repelling, vapor-open fabric, a rain screen located exterior
to the weather resistant barrier, the rain screen being adjacent to
outdoor space external to the energy efficient building and
including a drainage plane internal thereto, the drainage plane for
channeling moisture away from the weather resistant barrier;
insulation for placement within the structural layer and the
blanket layer; and wherein the at least one panelized structure is
air-sealed and insulated within the first and second sets of voids
after installation.
[0017] According to a second aspect of the present invention there
is provided a panelized wall structure for constructing an energy
efficient building, the panelized wall structure includes: a
structural layer having a first set of voids and located at an
inner area of the panelized wall structure, the inner area being
adjacent to intended living space of the energy efficient building;
an airtight layer formed by a first sheathing layer providing a
primary air barrier and a vapor retarder exterior to the structural
layer; a blanket layer located exterior to the first sheathing
layer and formed by a plurality of vertical members with a second
set of voids located between each of the vertical members; a
weather resistant barrier located exterior to the blanket layer and
including a second sheathing layer formed by an airtight,
water-repelling, vapor-open fabric; and a rain screen located
exterior to the weather resistant barrier, the rain screen being
adjacent to outdoor space external to the energy efficient building
and including a drainage plane internal thereto, the drainage plane
for channeling moisture away from the weather resistant
barrier.
[0018] According to a third aspect of the present invention there
is provided a panelized roof structure for constructing an energy
efficient building, the panelized roof structure for constructing
an energy efficient building, the panelized roof structure
includes: a structural layer having a first set of voids and
located at an inner area of the panelized roof structure, the inner
area being adjacent to intended living space of the energy
efficient building; an airtight layer formed by a first sheathing
layer providing a primary air barrier and a vapor retarder exterior
to the structural layer; a blanket layer located exterior to the
first sheathing layer and formed by a plurality of vertical members
with a second set of voids located between each of the vertical
members; a weather resistant barrier located exterior to the
blanket layer and including a second sheathing layer formed by an
airtight, water-repelling, vapor-open fabric; and a rain screen
located exterior to the weather resistant barrier, the rain screen
being adjacent to outdoor space external to the energy efficient
building and including a drainage plane internal thereto, the
drainage plane for channeling moisture away from the weather
resistant barrier.
[0019] Other aspects and features of the present invention will
become apparent to those ordinarily skilled in the art upon review
of the following description of specific embodiments of the
invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Embodiments of the present invention will now be described,
by way of example only, with reference to the attached Figures,
wherein:
[0021] FIG. 1 is a cross sectional side view of a south facing
building sidewall from ground to roof which illustrates various
building parts where the present invention may be embodied.
[0022] FIG. 2 is a schematic cross-sectional side view showing wall
o raft slab details incorporating the present invention.
[0023] FIG. 3 is a schematic cross-sectional side view showing a
heated basement detail having trussed flooring and incorporating
the present invention.
[0024] FIG. 4 is a schematic cross-sectional side view showing an
unheated basement detail having trussed flooring and incorporating
the present invention.
[0025] FIG. 5 is a schematic cross-sectional side view showing an
unheated basement detail with I-beam supported flooring and
incorporating the present invention.
[0026] FIG. 6 is a schematic cross-sectional top view showing an
exterior corner detail incorporating the present invention.
[0027] FIG. 7 is a schematic cross-sectional top view showing
marriage joint detail incorporating the present invention.
[0028] FIG. 8 is a schematic cross-sectional top view showing an
interior corner detail incorporating the present invention.
[0029] FIG. 9 is a schematic cross-sectional top view showing an
exterior wall to partition wall detail incorporating the present
invention.
[0030] FIG. 10A is a schematic cross-sectional side view showing a
door head detail incorporating the present invention.
[0031] FIG. 10B is a schematic cross-sectional side view showing a
door sill to slab detail incorporating the present invention.
[0032] FIG. 11B is a schematic cross-sectional plan view showing a
fixed window detail incorporating the present invention.
[0033] FIG. 11B is a schematic cross-sectional plan view showing an
operable window detail incorporating the present invention.
[0034] FIG. 12A is a schematic cross-sectional side view showing a
fixed window head detail incorporating the present invention.
[0035] FIG. 12B is a schematic cross-sectional plan view showing a
fixed window sill detail incorporating the present invention.
[0036] FIG. 12C is a schematic cross-sectional side view showing an
operable window head detail incorporating the present
invention.
[0037] FIG. 12D is a schematic cross-sectional plan view showing an
operable window sill detail incorporating the present
invention.
[0038] FIG. 13 is a schematic cross-sectional side view showing
floor to floor gable wall marriage detail incorporating the present
invention.
[0039] FIG. 14 is a schematic cross-sectional view through a
panelized roof incorporating the present invention.
[0040] FIG. 15 is a schematic cross-sectional view through a
panelized roof showing eave detail and incorporating the present
invention.
[0041] FIG. 16 is a schematic cross-sectional view through a
panelized roof showing ridge detail and incorporating the present
invention.
[0042] FIG. 17 is a schematic cross-sectional view through a
trussed roof incorporating the present invention.
[0043] FIG. 18 is a schematic cross-sectional view through a low
slope pitch roof incorporating the present invention.
DETAILED DESCRIPTION
[0044] The present invention is a system and method which provides
panelized, superinsulated building envelopes. In general, panel
sections in accordance with the invention are shop-fabricated as
completed assemblies or as partial assemblies and are installed as
components on a building site. Assemblies in accordance with the
present invention may include wall, roof, and floor assemblies.
Such assemblies provide a new and useful alternative to standard
SIPs such that the inventive assemblies are both thermal bridge
free and foam free.
[0045] All assemblies in accordance with the present invention are
designed and constructed to be highly energy efficient, resilient
and durable, and to meet the voluntary International Passive House
building energy standard and/or the Passive House Institute of the
United States building energy standard. It should be understood
that all parts of each building component or assembly are equally
important to the overall inventive system and method in order to
meet ideal building envelope performance goals and the
aforementioned energy standard.
[0046] With specific reference to the figures below, it should be
understood that like parts exists in more than one figure. As such,
each like part is numbered identically when like structures are
used throughout the various embodiments. For clarity, only the
first occurrence of such structures may be described in detail
where subsequent figures may not include a repeated description of
like structures.
[0047] With reference to the drawings, FIG. 1 is a compilation
which illustrates a variety of assemblies (shown in cross section)
which, once joined together on a building site with typical other
building components, form a panelized, superinsulated building
envelope embodying the invention. The inventive aspects of the
present invention therefore include the inventive assemblies, the
building system incorporating the assemblies, and the method by
which the assemblies thereby form the panelized, superinsulated
building envelope. In particular, FIG. 1 is a cross sectional side
view of a south facing building sidewall from ground to roof which
illustrates various building parts where the present invention may
be embodied. Here, a ground level section 4, mid-floor section 5,
and roof section 6 can be seen with first floor window 3 and second
floor window 2 located between sections. The inventive components
in FIG. 1 include panel assemblies 4a, 5a, 5c, and 6c which will be
further described in more detail related to FIGS. 2 through 18.
Commonly understood components such as foundation 4b, suspended
flooring 5d, roofing structure 6d, exterior roofing 6a are also
shown and which are pertinent to the present discussion as they
provide context in terms of implementation of the present
invention, though are not of particular importance in their
specific design as configurations may change given the particular
building architecture and/or site requirements. As well, exterior
overhangs 5b, 6b to shield direct sunlight rays (shown as dotted
line 1) are provided as shading devices which may be sized and
located so as to provide solar shading of the exposed window
frame.
[0048] With regard to FIG. 2, there is shown a schematic
cross-sectional side view showing wall to raft slab details
incorporating the present invention. Here, a panelized wall section
in accordance with the invention is secured atop a concrete slab
25. Beneath the slab 25 is foundation insulation 24 preferably
formed from 12-inch type II borate treated expanded polystyrene
(EPS) foam insulation. Mating pieces of additional foundation
insulation 20 surround the periphery of the slab 25 and are placed
under the overhanging end sheathing 18. The additional foundation
insulation is preferably formed from 12-inch type IX borate treated
EPS foam insulation. As shown, typical groundwork is provided
including large composition structural fill 21 and perimeter drain
23 run to daylight with a fabric 22 overlaid atop the drain 23 such
that the filter fabric separates granular fill from larger
composite structural fill over 4-inch.
[0049] As mentioned above, the present invention may be
incorporated within a building having a raft slab. As seen in FIG.
2, a concrete slab-on-grade foundation is a raft slab whereby
blocks made from borate-treated EPS (expanded polystyrene) are
provided below the concrete. Borate-treated EPS has been found to
be the most durable and benign plastic foam for this location. The
EPS blocks may be configured using dado and tenon joinery so as to
easily lock together block pieces. The interlocked blocks therefore
protect the concrete slab from thermal loss, isolating the interior
from radon and water vapor, and acting as a concrete form--all in
one system. Once the raft slab insulation is placed, an 8-inch
steel-reinforced concrete slab is poured which is thick enough that
separate footings are not required under point loads. The floor is
polished and sealed as a finished floor, or covered with another
material. The present invention incorporating such foundation
system is certified by the International Passive House Institute to
be free of thermal bridging, with a U value of 0.12 W/m.sup.2K
(0.021 Btu/hr ft.sup.2 .degree. F.), .apprxeq.R 47.6.
[0050] During installation, it is advantageous to install the walls
on top of the foundation vapor barrier to complete the air barrier.
As well, the use of adhesive sealant will complete the air barrier
connection from wall to foundation.
[0051] The panelized wall section portion of FIG. 2 includes
elements which can be grouped into five (5) basic categories.
Indeed, all panelized sections discussed herein below in accordance
with the present invention includes elements that may also be
grouped similarly into such five (5) basic categories. These
categories of elements include the structural layer, the airtight
layer, the blanket layer, the weather resistant barrier, and the
rain screen.
[0052] The structural layer forms an inner, structural wall. In
FIG. 2, this can be seen by internal wall 34 which is preferably
2.times.4 studs arranged 24-inch on center of #2 SPF
(spruce-pine-fir) or better per NELMA (Northeastern Lumber
Manufacturers Association). The base of internal wall 34 includes a
continuous 2.times.4 bottom plate 26. The bottom plate 26 secures
the panelized wall section to the slab 25 via an anchor bolt 28.
The structural layer may also include internal surfacing of gypsum
sheetrock 33 or any suitable interior surfacing product for the
given implementation. Within the voids between studs of the
internal wall 34, there is also provided mineral wool insulation
32.
[0053] The interior, structural wall 34 carries all structural
loads, with most insulation on the exterior, though it is left
uninsulated, as a "service cavity," until after the building
envelope is complete so as to facilitate panel attachments,
mechanical, and electrical work.
[0054] The airtight layer provides a structural diaphragm that is
also the primary air barrier and vapor retarder on the outside of
the structural layer. In terms of FIG. 2, this provided by the
continuous 2.times.4 bottom plate 26 being wrapped with a
weathertight tape such as Tescon Extoseal.RTM. sill tape available
from Pro Clima.RTM. of Schwetzingen, Germany or any suitable
weathertight tape. As well, the anchor bolt 28 is set in epoxy
adhesive 27 to ensure weathertight seal of bottom plate 26 to the
slab 25. A first sheathing layer 30 is provided adjacent to the
internal wall 34. This first sheathing layer 30 is preferably
constructed of a suitable weathertight coated OSB (oriented strand
board) such as 7/16-inch ZIP.RTM. sheathing available from Huber
Engineered Woods LLC of Charlotte, N.C.
[0055] The first sheathing layer 30 is rendered airtight with all
joints and nail holes taped with a suitable weatherproof taping
such as Tescon Vana.RTM. adhesive tape with fleece backing
available from Pro Clima.RTM. or any suitable weathertight tape.
Lastly, a vapor barrier 19 is provided to separate the slab 25 from
the exterior insulation 20, 24. The vapor barrier 19 may be a
continuous ten (10) mil polyethylene sheet or any suitable material
that functions as air barrier and capillary break. Thus, a
contiguous airtight layer is formed by the first sheathing layer 30
and vapor barrier 19 which are connected in a weathertight manner
at the continuous bottom plate 26. Moreover, it is beneficial that
the airtight layer is placed in a protected location, internal to
the panelized wall structure.
[0056] The blanket layer is an exterior insulating layer that
includes vertical members filled between with insulation. It should
be noted that the blanker layer is vapor open. As shown in FIG. 2,
each vertical member is an I-joist 29. Each I-joist 29 is
preferably an 117/8 inch I-joist arranged 24 inches on center with
SPF flanges and OSB webs. Between each I-joist 29 is a void which
is filled with a dense pack cellulose insulation 14 or similar
suitable insulating material. The blanket layer is held to the
structural layer by suitable screws 31 as shown and which are
preferably 5/16''.times.4'' RSS.TM. lag screws fastened at two feet
on center and staggered. RSS.TM. lag screws are a rugged structural
screw made of specially hardened steel and available from GRK
Fasteners of Schaumburg, Ill.
[0057] It should be understood that the "I-joists" referred to
herein are an engineered wood product consisting of solid wood or
laminated wood flanges and structural sheet material such as
plywood or OSB as the web and which are advantageously placed
outside the structural wall and air barrier, as support for
cladding and insulation. Attaching the I-joists to the structural
wall with structural screws thereby also is an advantage as the
panelized wall structure relies upon screws as the only structural
support for the blanket layer. For purposes allowing air evacuation
when installing blown insulation, holes may be drilled in the
I-joists of the blanket layer and covered with air-permeable mesh.
Cellulose insulation may be installed more densely than normal, at
4.0 to 4.25 pounds per cubic foot, to ensure that such insulation
remains in place during transport and for the life of the
building.
[0058] The blanket layer is insulated with cellulose to a minimum
density of 4.0 lbs/ft.sup.3, denser than typical to prevent
settling in the present invention's larger-than-typical insulation
cavities. The hygroscopic nature of cellulose insulation serves as
a moisture buffer and a mineral borate additive makes the cellulose
fireproof as well as resistant to pests. Testing has shown that
over time, the moisture content within the walls fluctuates
slightly, tracking environmental conditions, but that it stays far
below the levels required for mold growth.
[0059] With continued reference to FIG. 2, the weather resistant
barrier is formed partly by a second sheathing layer 11. This
second sheathing layer 11 is made of an airtight, water-repelling,
vapor-open fabric that is resistant to outdoor weather. The second
sheathing layer 11 should be a vapor-variable product which
protects against water vapor movement with a low permeance (e.g.,
of 0.17 Perms, on the cusp of a class 1 and class 2 vapor retarder,
but opens to 13.20 Perms (a class 3 vapor retarder)) which allows
for drying in the presence of high moisture content. The membrane
is reinforced to allow it to support dense-packed cellulose.
Preferably, the second sheathing layer 11 is fabricated from a
continuous Solitex Mento Plus.RTM. weather resistant barrier from
Pro Clima.RTM. with all joints taped with Tescon Vana.RTM. adhesive
tape with fleece backing available from Pro Clima.RTM. or any
suitable weathertight tape. Additionally, the overhanging end
sheathing 18 is also resistant to outdoor weather. Preferably, the
overhanging end sheathing 18 is constructed similar to the first
sheathing layer 30 and is preferably constructed of a suitable
weathertight coated OSB (oriented strand board) such as 7/16-inch
ZIP.RTM. sheathing and rendered airtight with all joints and nail
holes taped with a suitable weatherproof taping such as Tescon
Vana.RTM. adhesive tape or any suitable weathertight tape. Thus,
the second sheathing layer 11 and end sheathing 18 as a bottom
plate to encapsulate the blanket layer. Moreover, it should be
understood that sheet goods (plywood or OSB) at the top and bottom
of the I-joists 29 are provided as top and bottom plates to create
a cavity for blown insulation.
[0060] The fifth category of grouped elements of the panelized wall
section in accordance with the present invention is the rain screen
which includes the outermost parts shown in FIG. 2 adjacent the
exterior of the second sheathing layer 11. Vertical strapping 12 is
provided over the second sheathing layer 11 and preferably formed
by 1.times.3 SPF arranged 12'' on center. Upon the vertical
strapping 12 is secured horizontal strapping 13 preferably formed
by 1.times.3 SPF arranged 24' on center. The vertical strapping 12
and horizontal strapping 13 therefore form two layers of furring
material in a "flying batten" configuration to create a freely
draining "rain screen" drainage plane. The flying battens are
off-layout strips formed of the 1.times.3 strapping as mentioned
and are used to keep the second sheathing layer 11 from pushing too
far into the rain screen during and after cellulose installation.
The final outer layer of siding 15 is provided in any typical
manner such as standard 3/4 inch wood siding or as desired for the
given building's exterior decor requirements.
[0061] The vertical strapping 12 provides a gap at the bottom end
thereof where wall vent 16 is inserted. Preferably, the wall vent
17 is SV-5 Siding Vent available from Cor-A-Vent, Inc. of
Mishawaka, Ind. or any suitable heat-resistant webbing made from
profile extruded polypropylene plastic that functions as a drainage
mat for moisture collected in the area behind the siding 15. It
should also be noted that a termite shield 17 may be provided as is
typical to ward off wood eating insects. It should also be noted
that it is advantageous that the I-joists 29 are not bearing the on
the concrete slab 25.
[0062] Having discussed above what is fundamentally the basic
component of the present invention, namely a panelized wall
section, it should be understood that the following discussion of
subsequent FIGS. 3 through 18 are combinations of a variety of
configurations of panelized wall sections in accordance with the
present invention. As such, they are meant as illustrative of some
of the possible variations of the present invention, though other
combinations and sub-combinations may be well within the intended
scope of the present invention without straying from the
invention.
[0063] FIG. 3 includes several identical parts as previously shown
and described with regard to the panelized wall section portion of
FIG. 2. As such, those identical parts will not be again described,
but rather the differentiated parts will be discussed with regard
to FIG. 3. More specifically, FIG. 3 shows a schematic
cross-sectional side view showing a heated basement detail having
trussed flooring and incorporating the present invention. Here, a
section of suspended flooring structure is provided above a heated
basement. The suspended flooring structure includes a rimboard 35
abutting the first sheathing layer 30. Web joists 37 are situated
against the rimboard 35 and the bottom ends of each web joist 37
rest upon a sole plate 38. Subfloor 36 is provided in a known
manner across each web joist 37. In this configuration, it should
be noted that the internal wall 34 of the panelized wall section
resides atop the subfloor.
[0064] As the sole plate 38 is within the heated building envelope,
it need not be wrapped as was the bottom plate 26 shown in FIG. 2.
The sole plate 38 is secured in a typical fashion via anchor bolt
28 to the foundation wall 39. Likewise, in typical fashion, a
footing 43 supports the foundation wall 39. A break 100, common to
this and several following figures, in the foundation wall 39,
foundation insulation 24, and fill 21 is shown to indicate that the
height of the foundation structure may be longer than is shown. As
the foundation insulation 24 is foam which would otherwise degrade
when exposed to sunlight and weather, a layer of cement board 40
will normally be provided and typically will include a parge
coat.
[0065] With continued reference to FIG. 3 and forming part of the
weather resistant barrier, there is provided waterproofing 41 on
the exterior of the foundation wall 39. Such waterproofing 41 is
typically a fluid provided membrane known in the art. Likewise, a
capillary break 42 will be provided between the foundation wall 39
and the footing 43. The weather resistant barrier is thus formed in
the embodiment of FIG. 3 by the first sheathing layer 30
contiguously with the waterproofing 41, capillary break 42, and
vapor barrier 19.
[0066] FIG. 4 is similar to FIG. 3 except that the basement area is
unheated. Specifically, FIG. 4 is a schematic cross-sectional side
view showing an unheated basement detail having trussed flooring
and incorporating the present invention. In such configuration, the
weather resistant barrier providing the building's internal
envelope excludes the basement area. Here, it should be noted that
cellulose insulation 14 is provided within the suspended floor
structure among each web joist 37. Moreover, a membrane 44 is
provided under suspended floor structure against the bottom side of
each web joist 37, running atop the sole plate 38, and sealed to
the first sheathing layer 30. Such membrane 44 is preferably a high
performance airtight vapor control layer such as Pro Clima.RTM. DA
membrane. Thus while the waterproofing 41, capillary break 42, and
vapor barrier 19 contiguously provide a barrier layer to the
unheated basement area, the weather resistant barrier in the
configuration shown in FIG. 4 is primarily provided by the membrane
44 and the first sheathing layer 30.
[0067] FIG. 5 is similar to FIG. 4 except that the suspended floor
structure is more akin to the panelized wall section. Specifically,
FIG. 5 is a schematic cross-sectional side view showing an unheated
basement detail with I-beam supported flooring and incorporating
the present invention. The I-beams 46 are preferably 24 inches wide
and placed 16 inches on center. The I-beams 46 are engineered wood
joists such as TJI.RTM. Joists available from Weyerhaeuser of
Federal Way, Wash. A lower sheathing layer 45 is provided on the
underside of the I-beams 46 and is structural in its function as
well as forming part of the weather resistant barrier in this
embodiment. Like the first sheathing layer 30, the lower sheathing
layer 45 is rendered airtight with all joints and nail holes taped
with a suitable weatherproof taping such as Tescon Vana.RTM.
adhesive tape with fleece backing available from Pro Clima.RTM. or
any suitable weathertight tape. In this embodiment, the primary
airtight layer is formed by the first sheathing layer 30
contiguously with the lower sheathing layer 45.
[0068] A corner connection between two panelized wall sections in
accordance with the present invention is shown in FIG. 6 as a
schematic cross-sectional top view showing an exterior corner
detail. Dotted line 200 denotes the panel break between the two
panelized wall sections. Here, the screws 31 can be seen attaching
each I-joist 29 to studs in of the internal walls 34 so as to
attach the blanket layer to the structural layer. Because such
screws 31 can effectively break the airtight layer, portions of
taping 50 are provided suitable to prevent leakage at those
locations. Taping 50a is also provided at the exterior connection
between panelized wall sections.
[0069] With further regard to FIG. 6, the ends of each panelized
wall sections can be seen to include insulation board 49 which is
light weight stone wool insulation board such as ProRox.RTM. SL 960
made by ROXUL INC. of Milton, Ontario. Structural integrity of the
panelized wall sections at the corners is enhanced by the addition
of corner sheathing 51 which may be formed from a section of OSB.
At the corner interior, structural integrity is provided by a
C-stud formed by SPF studs 47a, 47b, 47c arranged in a
C-configuration with a foam insulation 48 located within any void
created at the center of the C-stud. In this configuration, the
airtight layer is formed by each first sheathing layer 30 and
assured by taping 50, 50a.
[0070] At outside corners of walls, holding I-joists back from the
ends of the airtight layer facilitates air sealing the vertical
seam at the outside corner where the airtight layer of two panels
meet. It may be useful to build one panel with extra second
sheathing layer 11 to be unfurled and sealed to the adjacent panel
after air sealing is complete. It is also possible to use a solid
sheet of sheathing material on one face only of the rain screen
layer, to facilitate panel connections while allowing the wall to
remain vapor-open at the adjacent face.
[0071] FIG. 7 is a schematic cross-sectional top view showing
marriage joint detail between panelized wall sections according to
the present invention. Again, dotted line 200 denotes the panel
break. Here, the insulation boards 49 are seen to abut. As well, it
should be understood that the second sheathing layer 11 is provided
between abutting insulations boards 49. Taping 50 assures the
airtight layer is contiguous between each first sheathing layer 30.
It may be also useful in configurations such as this, where two
wall panels meet in line, to break the panels off-layout (e.g., at
12'' for 24'' on center stud layout) to facilitate air sealing at
those locations. As well, it may be useful to build one panel with
extra second sheathing layer 11 so as to be unfurled and sealed to
the adjacent panel after air sealing is complete.
[0072] FIG. 8 is a schematic cross-sectional top view showing an
interior corner detail incorporating the present invention. Here,
an internal wall 34 is seen wrapping around an end of one panelized
wall section where a C-stud is formed by studs 47a, 47b, and 47c so
as to provide structural integrity to the corner section. It should
also be noted that the second sheathing layer 11 extends across
both insulation boards 49.
[0073] At inside corners of walls, holding I-joists back from the
inside corner may allow workers to reach into the deep framing
cavity to air-seal the vertical connection at the inside corner. It
may be useful to build one panelized wall section of the inside
corner with extra second sheathing layer 11 to be unfurled and
sealed to the adjacent panel after air sealing is complete. As
well, it may be useful at inside corners of walls to connect the
rain screens at adjacent panels with an L-shaped assembly of OSB or
other sheet stock, to provide a nailing base for siding.
[0074] FIG. 9 is a schematic cross-sectional top view showing an
exterior wall to partition wall abutting against one panelized wall
section in accordance with the present invention. In this
configuration, the weather resistant barrier formed by first
sheathing layer 30 remains intact and uninhibited by a partition
wall 34a. Here, an end stud of the partition wall 34a is joined to
the panelized wall section by way of a backer sheet 52a which may
be a section of plywood provided as a backing to drywall 33 and
into which the end stud of partition wall 34a may be suitably
fastened by way of screws.
[0075] FIGS. 10A and 10B illustrate a sliding glass doorway within
a panelized wall section embodying the present invention. In
particular, FIG. 10A shows a schematic cross-sectional side view
showing a door head detail while FIG. 10B is a schematic
cross-sectional side view showing a door sill to slab detail.
[0076] With reference to FIG. 10A, a nailer 52b is shown which may
be formed by a 11/2''.times.11/2'' section of SPF and to which a
plywood buck 59 may be suitably fastened. The plywood buck 59 is a
section of plywood suitably wrapped with a weathertight tape and
creating a window buck and which is taped via taping 50 to a header
60 to create a contiguous air barrier as part of the overall
weather resistant barrier. The header 60 provides structural
integrity to the door opening and is integrated into the edge of
internal wall 34 adjacent the plywood buck 59. Outer door frame 57a
operatively integrates with inner door frame 57b in a known
manner.
[0077] Window and door bucks (i.e., framing elements that surround
and support the fenestration) may be of two main parts, inner bucks
and outer bucks. The inner bucks are the structural support for the
fenestration, and are from 11/8'' to 11/2'' thick, located inside
the structural wall rough opening, extending to the inside of the
structural wall. The outer bucks are thinner, from 7/16'' to 3/4''
thick, placed outside and overlapping the inner bucks, extending to
the outside of the blanket layer. The buck assembly is wrapped with
one or more layers of solid wood to stiffen the assembly and to
provide a nailing surface. The two-step buck assembly serves to
minimize thermal bridging, provides positive placement for the
fenestration, and allows for insulation and drainage around the
window frame.
[0078] Glass 56 is preferably at least double paned with a warm
edge "Swiss spacer" 55 provided so as to proved enhanced insulative
value. As well, triple-pane glass panels perform even better than
the well-insulated frames it is preferably that all exterior doors
to be glass when used in the context of the present invention. Gaps
between the plywood buck 59 and the outer 54a and inner 54b trim
boards is filled respectively with foam type insulation 53 and 58
respectively. In particular, insulation 53 is preferably in the
form of a high quality insulating foam panel which may be easily
fashioned into the particular shape as shown, while insulation 58
may be in the form of water cured butyl fired urethane foam which
may be injected into the corresponding space. In this manner,
insulation 53 may be wrapped as shown with taping 50 to further
enhance the airtight layer. It should be noted that windows are
placed near the center of the wall thickness which may provide
aesthetic benefits as well as space for post-installation window
treatments.
[0079] The high performance panelized wall sections of the present
invention relatedly require high performance windows and exterior
doors. The present invention therefore works best in conjunction
with exterior doors that seal securely against air and water
infiltration. As well, triple-pane glass panels are preferred. It
is also preferable that all exterior doors to be glass when used in
the context of the present invention.
[0080] FIG. 10B shows the opposite end from FIG. 10A where an
exterior sill 61 abuts a lower frame 62 fabricated preferably from
a polyurethane product based on rigid foam with a high thermal
insulating value such as Purenit.RTM. available from Puren gmbh of
Uberlingen, Germany. A vapor barrier 19 is contiguously provided
under the lower frame 62 and along the slab 25 adjacent to
foundation insulations 20, 24. In this manner, the airtight layer
is formed by the double pane glass 56, spacer 55, inner door frame
57b, and vapor barrier 19. In general, doors are preferably placed
so they bear partly or in whole on the concrete slab.
[0081] FIGS. 11A through 12D show variations substantially similar
to the structure already shown and described in FIGS. 10A and 10B,
but related to fixed and operable windows.
[0082] FIGS. 11A and 11B are schematic cross-sectional plan views
showing, respectively, a fixed window detail and an operable window
detail incorporating the present invention with similar structure
and function of elements shown and described with regard to FIGS.
10A and 10B. It should be noted in both the placement of second
sheathing layer 11 extends around nailer 52b and the insulation 53
thereby ensuring a contiguous airtight, water-repelling, vapor-open
barrier to the blanket layer in either configuration.
[0083] FIGS. 12A through 12D are substantially similar to the
header and sill configurations of FIGS. 10A and 10B except that
these additional figures schematic cross-sectional side views
showing a fixed and operable window head and sill details
incorporating the present invention, thus parts are similarly
labeled. In each, it should be understood that the airtight layer
maintains the building envelope contiguously via the first
sheathing layer 30, the plywood buck 59 suitably wrapped with a
weathertight tape, the window frames (57a through 57c, depending
upon the fixed or operable configuration shown), and window glass
56, along with suitably placed taping 50 as shown.
[0084] In FIG. 13 there is shown a schematic cross-sectional side
view showing an example of a floor to floor gable wall marriage
detail incorporating panelized wall sections in accordance with the
present invention. Here, "marriage joints" allowing each panel to
be air-sealed and insulated after panel installation. Again, the
panel break 200 is shown to better view the separation between
panelized wall sections. Here, the interface between panelized wall
sections includes a set of horizontally oriented I-joists 63,
preferably formed by an 117/8 inch I-joist arranged 24 inches on
center with SPF flanges and OSB webs. Each horizontally oriented
I-joist 63 perpendicularly abuts the end of each I-joist 29.
[0085] With further regard to FIG. 13, a pair of insulation boards
49 are provided within the opposing voids in each horizontally
oriented I-joist 63. It should also be noted that that second
sheathing layer 11 is provided across insulation boards 49 thereby
ensuring a contiguous airtight, water-repelling, vapor-open barrier
to the blanket layer in either configuration. The flooring section
includes web joists 37 of which the outermost one abuts the first
sheathing layer 30 and rests between internal walls 34,
specifically upon top plate 65 as shown. Taping 50 is provided at
the joining of each horizontally oriented I-joist 63 against the
adjacent first sheathing layer 30 to provide contiguity in the
airtight layer. Extending the first sheathing layer 30 above the
blanket layer ends also facilitates air sealing the horizontal
marriage joint at floor-to-floor wall connections.
[0086] At wall top plates, it is also advantageous to let in strips
of air-sealing membrane to the airtight layer of each wall during
wall construction, to be connected to the roof airtight layer
during assembly, to complete the airtight layer. As well, holding
blanket layer top plates slightly lower than the roof slope is
beneficial to allow for discrepancies in construction.
[0087] During a typical installation like that shown in FIG. 13
where a panelized wall section is installed above another such
section, typically (but not limited to) second story cave walls,
the structural wall bears on top of the floor framing, but the
blanket layer extends down below the top of the second floor. The
second sheathing layer 11 may extend down to meet the (typically)
first floor airtight layer allowing a small construction gap, and
the joint is sealed with tape. The blanket layer does not extend
down as far, typically leaving a 6-8'' horizontal gap to be filled
with cellulose on site after air sealing is complete.
[0088] At gable walls, the panelized wall structures in accordance
with the present invention may advantageously also provide for
"balloon framing" of the structural wall either to span from the
bottom of the first floor to the ceiling of the second floor or
alternatively extending the framing to the top of the roof slope.
"Balloon framing" the entire wall assembly is also possible by
running structural components and blanket layer structure the full
height of the building. It is also possible to install and seal
blocking in the stud bays, in line with the ceiling air barrier, to
allow continuity of the air barrier between ceiling and walls.
[0089] While panelized wall sections have thus been described in
detail with regard to several configurations within a building, it
should further be noted that the present inventive concepts may
also be provided to a panelized roof section. Accordingly, FIGS. 14
through 18 relate to the present invention in regard to specifics
of roofing configurations. Again, like elements as previously
described are shown and labeled, though not discussed again as
their structure and function are as previously explained herein
above.
[0090] With specific reference to FIG. 14, there is shown a
schematic cross-sectional view through a panelized roof section
incorporating the present invention. Just as in the panelized wall
section of FIG. 2 et seq., the panelized roof section also includes
elements which can be grouped into five (5) basic categories which
include the structural layer, the airtight layer, the blanket
layer, the weather resistant barrier, and the rain screen.
[0091] The structural layer of the panelized roof section shown in
FIG. 14 includes rafters 71 which are preferably suitable
2.times.10 SPF studs arranged 24-inch on center, in a commonly
understood manner, ceiling strapping 64 from 1.times.3 SPF is
arranged 16-inch on center upon which internal surfacing of gypsum
sheetrock 33 or any suitable interior surfacing product for the
given implementation is affixed. Within the voids between rafters
71, there is also provided mineral wool insulation 32. The interior
framing system of rafters 71 carries all structural loads.
Connection of the roof airtight layer to the wall airtight layer
may be accomplished with flaps of second sheathing layer 11 that
project below the rafters 71.
[0092] The airtight layer provides a structural diaphragm that is
also the primary air barrier and vapor retarder on the outside of
the structural layer. In terms of FIG. 14, this is provided by root
sheathing 70. The root sheathing 70 is preferably constructed of a
suitable weathertight coated OSB (oriented strand board) such as
5/8-inch ZIP.RTM. sheathing and rendered airtight with all joints
and nail holes taped with a suitable weatherproof taping 50 such as
Tescon Vana.RTM. adhesive tape with fleece backing available from
Pro Clima.RTM. or any suitable weathertight tape.
[0093] In terms of FIG. 14, the blanket layer is the insulating
layer located exterior to the roof sheathing 70 and which includes
roofing I-joists 69 filled there between with cellulose insulation
14 or similar suitable insulating material. Each roofing I-joist 69
is preferably a 16-inch I-joist arranged 24 inches on center with
SPF flanges and OSB webs. The blanket layer is structurally screwed
(using structural screws) to the structural layer as shown with
taping 50 provided to render any corresponding holes airtight as
previously mentioned. It should be understood that sheet goods
(plywood or OSB) are provided at the top and bottom of the I-joists
as top and bottom plates so as to create a cavity for blown
insulation. For purposes allowing air evacuation when installing
blown insulation, holes may be drilled in the roofing I-joists 69
of the blanket layer and covered with air-permeable mesh. Cellulose
insulation may be installed more densely than normal, at 4.0 to
4.25 pounds per cubic foot, to ensure that such insulation remains
in place during transport and for the life of the building.
[0094] With continued reference to FIG. 14, the weather resistant
barrier is formed by the second sheathing layer 11 which, similar
to its use in the panelized wall sections, is made of an airtight,
water-repelling, vapor-open fabric that is resistant to outdoor
weather. It is advantageous that the placement of the second
sheathing layer 11 is in a protected location, above the rafters,
internal to the roof assembly.
[0095] The panelized roof section shown in FIG. 14 also includes a
rain screen which includes the outermost parts shown adjacent the
exterior of the second sheathing layer 11. Vertical roof strapping
68 is first suitably secured (e.g., via screws not shown) over the
second sheathing layer 11 and preferably formed by 1.times.3 SPF
arranged 24'' on center to abut each roofing I-Joist 69 as shown.
Upon the vertical roof strapping 68 is secured horizontal roof
strapping 66 preferably formed by 2.times.4 SPF purlins arranged
12'' on center so as to create a freely draining ventilation
channel. The final outer layer of roofing 67 is provided in any
typical manner such as standard sheet metal rooting or as desired
for the given building's exterior decor requirements. Installation
of roof strapping below the air barrier may be provided in a manner
thick enough to allow electrical conductors to be installed while
meeting code distance for fasteners.
[0096] Panelized roof sections may be pre-insulated at the factory
or post Insulated at the installation site. Leaving the ratter bays
uninsulated, as a "service cavity," until after the building
envelope is complete is beneficial so as to facilitate panel
attachments, mechanical and electrical work. Panelized roof
sections that are post-insulated may be provided in the form of
prefabricated trusses that are installed, air sealed, and insulated
on site, and may include structural support in the form of
shop-fabricated roof trusses, air sealing in the form of a membrane
below the trusses connected to the walls' airtight layer, and
insulation blown into the resulting attic cavity.
[0097] FIG. 15 is a schematic cross-sectional cave view through a
panelized roof section in conjunction with a panelized wall
section, each incorporating the present invention. Here, the
interface of the panelized roof section with the panelized wall
section is configured so as to ensure that the airtight layer is
contiguous and completely uninterrupted. More specifically, the end
of the panelized roof section is angled to provide desired pitch of
roofing 67. It should be noted that the wall rain screen cavity is
connected with the roof ventilation plane for fully ventilated
cladding.
[0098] A roofing rimboard 73 preferably formed of 11/8'' OSB
suitably wrapped with a weathertight tape. The roofing rimboard 73
abuts the first sheathing layer 30 with all joints including taping
50. As well, the airtight layer of the panelized wall section and
the airtight layer of the panelized roof section include a barrier
72 there between. The barrier 72 is preferably a high performance
airtight vapor control layer such as Pro Clima.RTM. DA, Intello, or
Intello Plus vapor retarder layers with all joints sealed by taping
50 preferably with Tescon Vana.RTM. or Rapid Cell.RTM. tape at all
seams and staples so as to provide a continuous air barrier. In
this configuration, the airtight layer is formed contiguously by
the roof sheathing 70, rimboard 73, barrier 72, and first sheathing
layer 30, and assured by taping 50.
[0099] When there are cave overhangs, it is advantageous to hold
the cave wall blanket layer top plates slightly lower than the
bottom of the truss top chord so as to allow the top chord to
extend over the top of the blanket layer. At cave walls and rake
walls, running the blanket layer vertically beyond the structural
wall top plate to meet (with a small construction gap) the roof
plane may be accomplished for the beneficial purpose of
over-insulating the roof framing.
[0100] FIG. 16 is a schematic cross-sectional view through
panelized roof sections (one in dotted line not labeled) showing
ridge detail and incorporating the present invention. Here, the
panelized roof sections attach to a ridge beam 75 using rafter
hangars 74. The interface between panelized roof sections atop the
ridge beam 75 is seen to include a gap which is filled with
insulation 48 which may be in the form of water cured butyl fired
urethane foam which may be injected into the corresponding space.
Taping 50 over the ends of abutting roof sheathing 70 ensures a
contiguous airtight layer. The interface of the blanket layers
includes a vertical gap in line with the ridge beam 75 and
insulation 48, and which vertical gap is filled with cellulose
insulation 14.
[0101] It is advantageous where two roof panels meet to build one
panel with extra second sheathing layer 11 so as to be unfurled and
sealed to the adjacent panel after air sealing is complete. It is
also advantageous where two roof panels meet at the ridge to leave
a cavity in the blanket layer to facilitate air sealing from above
and/or to build one panel with extra second sheathing layer 11 so
as to be unfurled and sealed to the opposite panel after air
sealing is complete.
[0102] FIG. 17 is similar to FIG. 15 except that FIG. 17 includes a
trussed roof. It should be readily apparent that the trussed roof
includes trusses 76 that may be of any suitable design
configuration corresponding to the given building requirements.
Here, the airtight layer is provided by way of membrane 72 secured
across the bottom of the given trusses 76 with taping 50 provided
at all seams and staples. Heavy ceiling strapping 77 is then
attached (e.g., via screws) to trusses 76 with the membrane 72
secured there between. In this configuration, the airtight layer is
formed contiguously by the membrane 72 and first sheathing layer
30, and assured by taping 50.
[0103] A 24'' raised heel truss roof is typically a cost effective
approach for a trussed roof design, insulated with loose-fill
cellulose to a depth of 24'' to 30'' for U values ranging from
0.071 to 0.045 W/m.sup.2K (0.0125 to 0.008 Btu/hr ft.sup.2 .degree.
F.). .apprxeq.R 80 to 120. The truss may be shaped like a
conventional gable, or it may be a mono-pitch (aka "shed roof"),
low-slope (aka "flat roof"), or other shapes. The economical choice
is for the truss to have a horizontal bottom chord, resulting in a
conventional flat ceiling, but it may also be scissor or parallel
chord trusses to create cathedral ceilings.
[0104] FIG. 18 is a schematic cross-sectional view through a low
slope pitch roof incorporating the present invention. Such a low
slope, or flat, roof may include layers having roof sheathing 78
such as ZIP System.RTM., fiber board 79, and EPDM (ethylene
propylene diene monomer (M-class) rubber) 80 with suitable seam
tape 81, drip edge 82, and fascia 83 which are known in the low
slope roofing art to provide a suitably durable low slop roofing
surface. In this configuration, a panelized roof section simply
abuts to a panelized wall section and rests on top plate 65 of the
internal wall 34. In this configuration, the airtight layer is
formed contiguously by the roof sheathing 70 and first sheathing
layer 30, and may also be assured by taping 50 over abutting ends
so as to ensure a contiguous airtight layer.
[0105] The wall assembly and corresponding system is certified by
the International Passive House Institute to be free of thermal
bridging, with a U-wall of 0.101 W/m.sup.2K (0.017 Btu/hr ft.sup.2
.degree. F.), .apprxeq.R 58.6. The related detailing the building's
exterior corners result in negative Psi (.psi.) values, meaning
that not only are they free of thermal bridging, they are a net
gain when performing heat loss calculations. The present invention
has a .psi. at building exterior corners is -0.068 W/mK (-0.039
Btu/h ft.sup.2 .degree. F.) and at building interior corners the
.psi. value is 0.026 W/mK (0.015 Btu/h ft.sup.2 .degree. F.). The
International Passive House Institute has also determined the
panelized roof sections to perform with a U value of 0.065
W/m.sup.2K (0.011 Btu/hr ft.sup.2 .degree. F.), .apprxeq.R 90. At
the cave connection with the exterior wall, typically a thermal
bridge, the inventive roof assembly has negative thermal bridging:
.psi.=-0.029 W/mK. At the ridge, another potential source of
problems, the marriage joint achieves .psi.=-0.029 W/mK
[0106] As mentioned, the inventive panel assemblies (i.e.,
panelized wall structures and panelized roof structures) are
shop-fabricated. In other words, the inventive assemblies are
assembled primarily in a climate controlled facility which ensures
high quality in construction and enables tight tolerances of all
assembly dimensions. Panel size for each assembly is of course
dictated by the given project's geometry, equipment constraints,
and trucking restrictions. Following installation on site, each of
the airtight layer, the blanket layer insulation, and the weather
resistant barrier is completed at the marriage joints. Use of a
crane may facilitate panel setting, while shipping of the panels
may be provided horizontally on a trailer. It may be preferable to
utilize waler boards (i.e., framing lumber attached to stakes in
the ground) outside the building to brace wall panels as they are
erected, as opposed to typical interior wall bracing which also
advantageously protects the concrete slab from damage.
[0107] With further reference to FIG. 2, it should also be noted
that the foundation insulation 20, 24 and corresponding slab 25 may
provide unique innovations in the combination as shown. More
specifically, a raft slab foundation that is a well-insulated,
self-forming foundation system may be provided that includes EPS
foam, in customizable interlocking shapes, to form the perimeter
and "frost wing" (i.e., the portion which extends beyond the
concrete slab). The customizable interlocking shapes may interlock
with the frost wing to create a perimeter form for the concrete
slab. As well, the EPS foam may be provided in simple rectangular
form to create sub-slab insulation.
[0108] The foam components are prefabricated in a shop. Following
site preparation, the foam components are set on the site, sealed
together with sprayed foam, the vapor barrier is installed,
concrete reinforcing is installed, and the concrete slab is poured
into the EPS foam "raft." At a nominal 8'', the concrete slab is
thick enough that additional structural support in the form of
footings is not typically required. Moreover, the foam insulation
protects the slab from thermal losses. Such innovative raft slab
foundations may beneficially provide features including the use of
borate-treated EPS foam for all components and the use of different
densities of EPS for different locations.
[0109] The shape of a "frost wing" portion of such a raft slab
system may involve including a wing projecting beyond the building
with a groove which receives the slab form and sloped to shed
water. The shape of the "slab form," L-shaped in section, which
interlocks with the frost wing advantageously creates an 8'' tall
form for the concrete slab. The raft slab system may feature:
infilling the frost wing perimeter with rectangular blocks of
borate-treated EPS foam; specific dimensioning of all parts; using
component dimensions adequate to meet the Passive House standard in
cold climates; having all parts cut to shape and length, including
mitered wings at inside and outside corners; leaving gaps between
all components, pending application of spray foam adhesive sealant;
using spray foam adhesive sealant to connect all components; using
blocks of foam offcuts to support steel reinforcing before the
concrete slab is poured; following the concrete pour, wrapping the
vapor barrier membrane onto the top surface of the concrete and
sealing it with tape so as to be later connected with the wall air
barrier; and backfilling over the frost wing with soil for
protection and aesthetic reasons.
[0110] Still further, assemblies in accordance with the present
invention may form a pier foundation that minimizes or eliminates
the use of plastic foam and concrete, as both products have certain
negative environmental impacts. A pier foundation utilizing helical
metal piles or other forms of support, depending on various
conditions, sized per building code and industry best practices may
therefore benefit from the present panelized wall and roof
structures. Above the piers, panelizing construction of the floor
system may be provided in accordance with the same principles and
features shown and described herein above with regard to the
inventive panelized wall and roof structures.
[0111] As mentioned, for projects where treading lightly on the
land is a key concern, eliminating plastic foam is a goal, or
access to the site is compromised, a pier foundation may be used.
Using helical piers--galvanized metal posts with an auger screw at
the bottom, literally drilled into the ground--minimizes
disturbance of the site. The floor is framed with deep I-joists and
filled with dense-packed cellulose, with an airtight,
moisture-repelling skin applied to the bottom of the floor system.
A small, insulated chase may be used to bring utilities into a
central location. The same insulated floor system used for piers
may be used on an uninsulated foundation or crawlspace. The present
invention utilized with a foam-free framed floor system uses 24''
I-joists filled with dense-packed cellulose, with assembly
insulation values of 0.070 W/m.sup.2K (0.012 Btu/hr ft.sup.2
.degree. F.), .apprxeq.R 83.3.
[0112] It should be readily understood that the present invention
advantageously allows in-shop fabrication of building components
and assemblies thus ensuring quality control and fast, accurate
installation on site. As well, this allows for configuring building
components and assemblies for ease of loading and trucking flat
(horizontally) on a flatbed trailer. Such in-shop fabrication of
building components and assemblies thereby enable building envelope
performance much greater than that provided by standard
construction techniques.
[0113] The above-described embodiments of the present invention are
intended to be examples only. Alterations, modifications and
variations may be effected to the particular embodiments by those
of skill in the art without departing from the scope of the
invention, which is defined solely by the claims appended
hereto.
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