IBACOS INC — Department of Energy SBIR Phase II: C54-20a

Description

Retrofitting existing wall cladding, or re-siding, occurs on approximately 2 million homes per year in America. In most cases, exterior continuous insulation or a rainscreen drainage system is not included in these retrofits. This is likely due to the cost of these additional layers, the added labor effort, or lack of experience and skill on proper installation practices. As an option, there are a few vinyl siding manufacturers that have incorporated a small amount of expanded polystyrene (EPS) foam to the back of the siding; however, this foam varies in thickness due to the profile of the siding and provides an average weighted R-value of approximately R-2.5-3. This siding is not widely used due to the minimal thermal improvement and the premium cost associated with the product. Through Phase I of this SBIR project, the team investigated the technical feasibility of a new siding product that incorporates three functions – finished siding, R-6.5 insulation and an integral rainscreen into a single product. This system delivers a cost-effective and easier way to improve the thermal performance of existing homes undergoing an exterior aesthetic rehab, or an energy efficiency retrofit. This insulated siding system is also a viable solution to meeting continuous insulation requirements for new home construction. This insulated siding technology utilizes an engineered wood siding product bonded to a layer of 1” polyisocyanurate rigid board insulation to provide an R-value of R-6.5. The polyisocyanurate has 1/4” grooves routed out on the back side to provide integral rainscreen drainage, for a total combined product thickness of less than 1.5”. The finished siding has a standard shiplap design milled into the material that, when installed, creates a “nickel gap” aesthetic between the individual planks. The insulation board has been designed and profiled with precise opposing 45-degree angles along the top and bottom horizontal edges of the boards. This profile enables an airtight, water draining insulated siding and allows a single installer to easily set the planks on top of one another and the opposing angles of the insulation and shiplap create a self-aligning assembly. This installer friendly retrofit wall system incorporates integrated layers for cladding, thermal resistance, vapor retardance, and water drainage into one product for improved performance, installer productivity, and cost. Based on Phase I results, the insulated siding technology shows potential energy savings of 11.5% - 34.75% across three different cities (Minneapolis, Phoenix, Pittsburgh), compared to an uninsulated or minimally insulated (R-11) and a projected operational carbon emissions reduction of 0.4-4.48 metric tons. Phase II funding will provide the needed resources to further refine the initial proof of concept and develop the manufacturing processes to produce a market ready product that can meet the needs of the retrofit and new construction industries. Two demonstration homes will be completed to evaluate installation productivity, energy comfort, and moisture performance, and aesthetic appeal.