SIPs share the same structural properties as an I-beam or I-column. The rigid insulation core of the SIP acts as a web, while the sheathing fulfills the function of the flanges. SIPs combine several components of conventional building, such as studs and joists, insulation, vapor barrier and air barrier. They can be used for many different applications, such as exterior wall, roof, floor and foundation systems.
History
Standard OSB with EPS-core structural insulated panel
Although foam-core panels gained attention in the 1970s, the idea of using stress-skinned panels for construction began in the 1930s. Research and testing of the technology was done primarily by Forest Products Laboratory (FPL) in Madison, Wisconsin, as part of a U.S. Forest Service attempt to conserve forest resources. In 1937, a small stressed-skin house was constructed and garnered enough attention to bring in First Lady Eleanor Roosevelt to dedicate the house. In a testament to the durability of such panel structures, it endured the Wisconsin climate and was used by University of Wisconsin–Madison as a day care center until 1998, when it was removed to make way for a new Pharmacy School building. With the success of the stress-skinned panels, it was suggested stronger skins could take all the structural load and eliminate the frame altogether.
Thus in 1947, structural insulated panel development began when corrugated paperboard cores were tested with various skin materials of plywood, tempered hardboard and treated paperboard. The building was dismantled in 1978, and most of the panels retained their original strength with the exception of paperboard, which is unsuited to outdoor exposure. Panels consisting of polystyrene core and paper overlaid with plywood skins were used in a building in 1967, and as of 2005[update] the panels performed well.
SIP systems were used by Woods Constructors of Santa Paula, California, in their homes and apartments from 1965 until 1984. This work was the basis for John Thomas Woods, Paul Flather Woods, John David Woods, and Frederick Thomas Woods when they used a similar concept to patent the Footing Form for Modular homes (US Patent No.4817353) issued on April 4, 1989. Numerous homes in Santa Paula, Fillmore, Palm Springs, and surrounding areas use SIPs as the primary method of construction. The design was awarded approval from (then) ICBO and SBCCI, now ICC.
Materials
SIPs are most commonly made of OSB panels sandwiched around a foam core made of expanded polystyrene (EPS), extruded polystyrene (XPS) or rigid polyurethane foam. Other materials can be used in replacement of OSB, such as plywood, pressure-treated plywood for below-grade foundation walls, steel,[1] aluminum, cement board such as Hardiebacker, and even exotic materials like stainless steel, fiber-reinforced plastic, and magnesium oxide. Some SIPs use fiber-cement or plywood sheets for the panels, and agricultural fiber, such as wheat straw, for the core.
The third component in SIPs is the spline or connector piece between SIPs. Dimensional lumber is commonly used but creates thermal bridging and lowers insulation values. To maintain higher insulation values through the spline, manufacturers use Insulated Lumber, Composite Splines, Mechanical Locks, Overlapping OSB Panels, or other creative methods. Depending on the method selected, other advantages such as full nailing surfaces or increased structural strength may become available.
SIP's are most often manufactured in a traditional factory. Processing equipment is used to regulate pressures and heat in a uniform and consistent manner. There are two main processing methods which correspond to the materials used for the SIP core. When manufacturing a panel with a polystyrene core both pressure and heat are required to ensure the bonding glue has penetrated and set completely. Although a number of variations exist, in general, the foam core is first covered with an adhesive and the skin is set in place. The three pieces are set into a large clamping device and pressure and heat are applied. The three pieces must stay in the clamping device until the glue has cured.
When manufacturing a panel with a polyurethane core pressure and heat are both generated from the expansion of the foam during the foaming process. The skins are set in a large clamping device which functions as a mold. The skins must be held apart from each other to allow the liquid polyurethane materials to flow into the device. Once in the device, the foam begins to rise. The mold/press is generally configured to withstand the heat and the pressures generated from the chemical foaming. The SIP is left in the mold/press to cure slightly and when removed will continue to cure for several days.
Until recently, both of these processes required a factory setting. However, recent advancements have presented an alternative with SIP processing equipment that allows SIPs to be manufactured on the job-site. This is welcome news for builders in developing countries where the technology may be best suited to reduce greenhouse emissions and improve sustainability in housing but are unavailable.
Benefits and drawbacks
The use of SIPs brings many benefits and some drawbacks compared to a conventional framed building.
The costs of SIPs are higher than the materials for a comparable framed building in the United States; however, this may not be true elsewhere. A well-built home using SIPs will have a tighter building envelope and the walls will have higher insulating properties, which leads to fewer drafts and a decrease in operating costs. Also, due to the standardized and all-in-one nature of SIPs, construction time can be less than for a frame home, as well as requiring fewer tradespeople. The panels can be used as floor, wall, and roof, with the use of the panels as floors being of particular benefit when used above an uninsulated space below. As a result, the total life-cycle cost of a SIP-constructed building will, in general, be lower than for a conventional framed one—by as much as 40%. Whether the total construction cost (materials and labor) is lower than for conventional framing appears to depend on the circumstances, including local labor conditions and the degree to which the building design is optimized for one or the other technology.
An OSB skinned system structurally outperforms conventional stick framed construction in some cases; primarily in axial load strength. SIPs maintain similar versatility to stick framed houses when incorporating custom designs. Also, since SIPs work as framing, insulation, and exterior sheathing, and can come precut from the factory for the specific job, the exterior building envelope can be built quite quickly. SIPs panels also tend to be lightweight and compact which aids this offsite construction. The environmental performance of SIPs, moreover, is very good due to their exceptional thermal insulation. They also offer a resistance to damp and cold problems like compression shrinkage and cold bridging that cannot be matched by timber and more traditional building materials.[2]
When tested under laboratory conditions, the SIP, included in a wall, foundation, floor, or roof system, is installed in a steady-state (no air infiltration) environment; systems incorporating fiberglass insulation are not installed in steady-state environments as they require ventilation to remove moisture.
With the exception of structural metals, such as steel, all structural materials creep over time. In the case of SIPs, the creep potential of OSB faced SIPs with EPS or polyurethane foam cores has been studied and creep design recommendations exist.[3][4] The long-term effects of using unconventional facing and core materials require material specific testing to quantify creep design values.
Dimensions and characteristics
In the United States, SIPs tend to come in sizes from 4 feet (1.22m) to 24 feet (7.32m) in width. Elsewhere, typical product dimensions are 300, 600, or 1,200mm wide and 2.4, 2.7, and 3m long, with roof SIPs up to 6m long. Smaller sections ease transportation and handling, but the use of the largest panel possible will create the best insulated building. At 15−20kg/m2, longer panels can become difficult to handle without the use of a crane to position them, and this is a consideration that must be taken into account due to cost and site limitations. Also of note is that when needed for special circumstances longer spans can often be requested, such as for a long roof span. Typical U.S. height for panels is eight or nine feet (2.44 to 2.75 m). Panels come in widths ranging from 4 to 12inches thick and a rough cost is $4–$6/ft2 in the U.S.[5] In 4Q 2010, new methods of forming radius, sine curve, arches and tubular SIPs were commercialized. Due to the custom nature and technical difficulty of forming and curing specialty shapes, pricing is typically three or four times that of standard panels per foot.[6]
EPS is the most common of the foams used and has an R-value (thermal resistance) of about 4 °F·ft2·h/BTU (equivalent to about 0.7 K·m2/W) per 25mm thickness, which would give the 3.5 inches (89mm) of foam in a 4.5-inch-thick (110mm) panel an R value of 13.8 (caution: extrapolating R-values over thickness may be imprecise due to non-linear thermal properties of most materials). This at face value appears to be comparable to an R-13 batt of fiberglass, but because in a standard stick frame house there is significantly more wall containing low R value wood that acts as a cold bridge, the thermal performance of the R-13.8 SIP wall will be considerably better.
The air sealing features of SIP homes resulted in the Environmental Protection Agency's Energy Star program to establish an inspection protocol in lieu of the typically required blower door test to assess the home's air leakage. This serves to speed the process and save the builder/homeowner money.
The International Building Code references APA, Plywood Design Specification 4—Design & Fabrication of Plywood Sandwich Panels for the design of SIPs.[7] This document addressed the basic engineering mechanics of SIPs but does not provide design properties for the panels provided by any specific manufacturer. In 2007, prescriptive design provisions for OSB faced SIPs were first introduced in the 2006 International Residential Code. These provisions provide guidance on the use of SIPs as walls panels only.
Aside from these non-proprietary standards, the SIP industry has relied heavily on proprietary code evaluation reports. In early 2009, SIPA partnered with ICC NTA, LLC, a third-party product evaluation certification agency, to produce the first industry wide code report which is available to all SIPA members who qualify. Unlike previous code reports, the prescriptive provisions provided in the SIPA code report are derived from an engineering design methodology which permits the design professional to consider loading conditions not addressed in the code report.[4][8]
Related Research Articles
Styrofoam is a trademarked brand of closed-cell extruded polystyrene foam (XPS), manufactured to provide continuous building insulation board used in walls, roofs, and foundations as thermal insulation and as a water barrier. This material is light blue in color and is owned and manufactured by DuPont. DuPont also has produced a line of green and white foam shapes for use in crafts and floral arrangements.
In the context of construction, the R-value is a measure of how well a two-dimensional barrier, such as a layer of insulation, a window or a complete wall or ceiling, resists the conductive flow of heat. R-value is the temperature difference per unit of heat flux needed to sustain one unit of heat flux between the warmer surface and colder surface of a barrier under steady-state conditions. The measure is therefore equally relevant for lowering energy bills for heating in the winter, for cooling in the summer, and for general comfort.
Engineered wood, also called mass timber, composite wood, human-made wood, or manufactured board, includes a range of derivative wood products which are manufactured by binding or fixing the strands, particles, fibres, or veneers or boards of wood, together with adhesives, or other methods of fixation to form composite material. The panels vary in size but can range upwards of 64 by 8 feet and in the case of cross-laminated timber (CLT) can be of any thickness from a few inches to 16 inches (410 mm) or more. These products are engineered to precise design specifications, which are tested to meet national or international standards and provide uniformity and predictability in their structural performance. Engineered wood products are used in a variety of applications, from home construction to commercial buildings to industrial products. The products can be used for joists and beams that replace steel in many building projects. The term mass timber describes a group of building materials that can replace concrete assemblies.
Straw-bale construction is a building method that uses bales of straw as structural elements, building insulation, or both. This construction method is commonly used in natural building or "brown" construction projects. Research has shown that straw-bale construction is a sustainable method for building, from the standpoint of both materials and energy needed for heating and cooling.
This page is a list of construction topics.
Insulating concrete form or insulated concrete form (ICF) is a system of formwork for reinforced concrete usually made with a rigid thermal insulation that stays in place as a permanent interior and exterior substrate for walls, floors, and roofs. The forms are interlocking modular units that are dry-stacked and filled with concrete. The units lock together somewhat like Lego bricks and create a form for the structural walls or floors of a building. ICF construction has become commonplace for both low rise commercial and high performance residential construction as more stringent energy efficiency and natural disaster resistant building codes are adopted.
A vacuum insulated panel (VIP) is a form of thermal insulation consisting of a gas-tight enclosure surrounding a rigid core, from which the air has been evacuated. It is used in building construction, refrigeration units, and insulated shipping containers to provide better insulation performance than conventional insulation materials.
ThermaSAVE is a panel building system which uses a 4 to 12-inch-thick core of expanded polystyrene sandwiched between two sheets of cellulose fiber-reinforced cement board varying in thickness from 3/8 to 7/16 inch, depending on structural requirements. This creates a "stress skinned" panel, also known as structural insulated panels (SIPs). Since c. 1984 H.H. "Hoot" Haddock from Florence, Alabama has been working on perfecting a polystyrene-based building system that would be faster and easier to construct than wood-framed buildings, while having superior insulation and strength.
Polyisocyanurate, also referred to as PIR, polyiso, or ISO, is a thermoset plastic typically produced as a foam and used as rigid thermal insulation. The starting materials are similar to those used in polyurethane (PUR) except that the proportion of methylene diphenyl diisocyanate (MDI) is higher and a polyester-derived polyol is used in the reaction instead of a polyether polyol. The resulting chemical structure is significantly different, with the isocyanate groups on the MDI trimerising to form isocyanurate groups which the polyols link together, giving a complex polymeric structure.
Precast concrete is a construction product produced by casting concrete in a reusable mold or "form" which is then cured in a controlled environment, transported to the construction site and maneuvered into place; examples include precast beams, and wall panels for tilt up construction. In contrast, cast-in-place concrete is poured into site-specific forms and cured on site.
A cavity wall is a type of wall that has a hollow center. They can be described as consisting of two "skins" separated by a hollow space (cavity). The skins typically are masonry, such as brick or cinder block. Masonry is an absorbent material that can slowly draw rainwater or even humidity into the wall. One function of the cavity is to drain water through weep holes at the base of the wall system or above windows. The weep holes allow wind to create an air stream through the cavity that exports evaporated water from the cavity to the outside. Usually, weep holes are created by separating several vertical joints approximately two meters apart at the base of each story. Weep holes are also placed above windows to prevent dry rot of wooden window frames. A cavity wall with masonry as both inner and outer skins is more commonly referred to as a double wythe masonry wall.
In materials science, a sandwich-structured composite is a special class of composite materials that is fabricated by attaching two thin-but-stiff skins to a lightweight-but-thick core. The core material is normally of low strength, but its greater thickness provides the sandwich composite with high bending stiffness with overall low density.
Building insulation is material used in a building to reduce the flow of thermal energy. While the majority of insulation in buildings is for thermal purposes, the term also applies to acoustic insulation, fire insulation, and impact insulation. Often an insulation material will be chosen for its ability to perform several of these functions at once.
Building insulation materials are the building materials that form the thermal envelope of a building or otherwise reduce heat transfer.
A thermal bridge, also called a cold bridge, heat bridge, or thermal bypass, is an area or component of an object which has higher thermal conductivity than the surrounding materials, creating a path of least resistance for heat transfer. Thermal bridges result in an overall reduction in thermal resistance of the object. The term is frequently discussed in the context of a building's thermal envelope where thermal bridges result in heat transfer into or out of conditioned space.
Spray foam is a chemical product created by two materials, isocyanate and polyol resin, which react when mixed with each other and expand up to 30-60 times its liquid volume after it is sprayed in place. This expansion makes it useful as a specialty packing material which forms to the shape of the product being packaged and produces a high thermal insulating value with virtually no air infiltration.
Rigid panel insulation, also referred to as continuous insulation, can be made from foam plastics such as polyurethane (PUR), polyisocyanurate (PIR), and polystyrene, or from fibrous materials such as fiberglass, rock and slag wool. Rigid panel continuous insulation is often used to provide a thermal break in the building envelope, thus reducing thermal bridging.
A sandwich panel is any structure made of three layers: a low-density core, and a thin skin-layer bonded to each side. Sandwich panels are used in applications where a combination of high structural rigidity and low weight is required.
Cladding is the application of one material over another to provide a skin or layer. In construction, cladding is used to provide a degree of thermal insulation and weather resistance, and to improve the appearance of buildings. Cladding can be made of any of a wide range of materials including wood, metal, brick, vinyl, and composite materials that can include aluminium, wood, blends of cement and recycled polystyrene, wheat/rice straw fibres. Rainscreen cladding is a form of weather cladding designed to protect against the elements, but also offers thermal insulation. The cladding does not itself need to be waterproof, merely a control element: it may serve only to direct water or wind safely away in order to control run-off and prevent its infiltration into the building structure. Cladding may also be a control element for noise, either entering or escaping. Cladding can become a fire risk by design or material.
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