Affordable Panelized Wall System

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29 Νοε 2013 (πριν από 3 χρόνια και 9 μήνες)

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Affordable Panelized
Wall
System

Group 15

John Mitchell

Chris McNeill

Samantha Gonzales

Heidi
Sookram


Department of Mechanical Engineering

FAMU
-

FSU College of Engineering

11/29/2013

1

Outline


Introduction


Design Selection


Product Specifications


Design Explanation


Panel Manufacturing


Testing and Analysis


Cost Analysis


Future Considerations


Acknowledgements



11/29/2013

2

Introduction


Design a wall panel to lower the cost of home
ownership over a 60 year period.


Exterior walls of a home for affordable
housing


Utilize volunteer’s


Must be small enough to not require heavy
lifting equipment


LEED Compliant







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3

Types of Panel Systems

Metal Frame Wall
Panel

Wood Frame
Open Wall Panel

Pre
-
Formed
Concrete Wall Panel

Wood SIP
Wall Panel

Images source: www.huduser.org/Publications/PDF/path_panel_conntn_report.pdf

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4

Design Selection

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5

Product Specification

Table

1
-

Product Specifications

Specification

Value

Panel Size

4 ft. x 8 ft.

Dead Load Capacity

40 psf

Live Load Capacity

80 psf

Variable R
-
Value*

14, 24, 30 *

Wind Speed

130 mph wind zone

Seismic Category

A, B, C

Insulation Material

EPS Foam

Insulation Density

1.8 lbs/cubic ft

Sheathing Material

Structural OSB

Sheathing Density

45 lb/cubic ft.

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6

What is a wood SIP?


2 pieces of OSB sandwiching a block of insulating foam


Devise a method to connect panel at all points


Panel to panel


Panel to floor and roof


Corner connections

**
Include pro/e drawings of each connection type

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7

Manufacturing

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8

Panel Manufacturing

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9


Adhesive chemical reaction pushes OSB away
from foam






Need to find a method to offset the reaction

EPS Foam

OSB

Panel Manufacturing

Vacuum bag
preparation

Roll adhesive over
both sides of foam

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10

Panel ready for
compression

Pump pulls air out to compress
panel at 15 psi for 2 hours

Panel Testing and Analysis

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11


Structural FE Analysis


Doubled design load requirement to 240 psf.


Maximum stress ~ 1300psf


Concentrated in corners

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12

Deflection Testing

The total span is 7.5 ft.

The panel deflected 3/8” under a
load of
1440 lbs.

The panel deflected 1.25” under
a load of
3400 lbs

Bags

Mass(
lbm
)

Deflection (In)

Difference

0

0

0

0

9

720

0.1250

0.1250

15

1200

0.3125

0.1875

18

1440

0.3750

0.0625

21

1680

0.5000

0.1250

25

2000

0.6250

0.1250

27

2160

0.6875

0.0625

33

2640

0.8125

0.1250

39

3120

1.1250

0.3125

42

3360

1.2500

0.1250


Simulated pressure load from high winds


1 ¼” deflection under 112 psf load.


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13

Wind Load Analysis


Same static load


86.5 psf load applied perpendicular to wall surface


Result was wall deflection


Maximum stress achieved is 15,600 psf

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14

Long Term Cost Analysis

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15

Cost Analysis


Our Goal


Lowest total cost of ownership over 60 years



Two main components of overall cost


1)

Initial construction cost


2)

Cost of operation over lifespan of home


Set up reference house for basis of comparison


Traditional wood framed house


2”x4” stud construction


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16

Material Cost


Wood Frame


Sill plate


Dimensional lumber


Studs


Plywood siding


Fiberglass batt insulation, R
-
13


Gypsum wallboard


Vinyl siding




Wood SIP


Sill plate


Dimensional lumber


Structural grade OSB


EPS foam core


Adhesive


Gypsum wallboard


Vinyl siding


Initial Construction Cost for Exterior Wall

Wood frame

4 ½’ wood SIP

6 ½’ wood SIP

8 ½’ wood SIP

$1,972

$3,281

$3,871

$4,521

+ $1,309

+ $591

+ $650

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17

Annual Energy Cost


EnergyGauge USA home energy simulation software


Model home


1120 ft
2

floor area


Concrete slab foundation


76 ft
2

window area


double pane windows


R30 insulated roof


Appliances


Different Exterior Walls


All other parameters constant

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18

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19

Annual Energy Cost

Annual Energy Cost

Traditional
wood

frame, 2’x4’

4 ½’ wood
SIP

6 ½’ wood
SIP

8 ½’ wood
SIP

Caribou,
MN

$1,198

$1,020

$952

$933

Forks of
Salmon, CA

$1,008

$849

$822

$810

Gnaw Bone,
IN

$977

$827

$792

$778

Flamingo,
FL

$791

$735

$727

$723

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20

Long Term Energy Cost


Account for costs over 60 years


Annual energy costs transformed into Present Value using geometric
series present worth factor:





n
n
n
n
e
i
GP
i
e
i
e
i
T
)
1
)(
(
]
)
1
(
)
1
[(
,
,
,






n
e
i
GP
GT
P
,
,
,

G =
first year payment

i

= annual interest rate,
3%,

e
= annual escalation of
electricity cost, 5%

n

= number of years


5 years

10 years

25 years

60 years

Present

worth
factor

5.05

10.6

30.86

108.52

n
e
i
GP
GT
t
InitialCos
TotalCost
,
,
,


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21

Long Term Total Cost
(ex. Minnesota)


Caribou, MN

Traditional
wood

frame, 2’x4’

4 ½’ wood SIP

6 ½’ wood SIP

8 ½’ wood SIP

5 years

$8,017.46

$8,428.04

$8,675.57

$9,229.66

10 years

$14,673.48

$14,095.10

$13,964.83

$14,413.36

25 years

$38,950.43

$34,764.96

$33,256.70

$33,320.20

60 years

$131,983.16

$113,974.79

$107,185.87

$105,773.90

Savings
compared to
wood frame
construction

$18,008.37

$24,797.28

$26,209.26

Relative savings
between SIP
designs

$6,788.92

$8,200.89

$1,411.97

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22

Overall Cost 60 Year

Wood Frame

6 ½” SIP

(4½” Flamingo)

Savings

Baudette, MN

$131,723.16

$106,925.87

$24,797.28

Forks of Salmon,
CA

$111,103.64

$92,817.78

$18,285.86

Gnaw Bone, IN

$107,739.40

$89,562.07

$18,177.33

Flamingo, FL

$4,768.46

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23

Concluding Remarks


Wood SIP is the simplest design


Panel Manufacturing is straight forward


Shows promising results under adverse weather conditions


Higher initial cost, Lower long term cost


Easy to implement into an affordable housing program





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24

Future Considerations


Confirm capacity for seismic resistance using full scale model


Perform structural analysis utilizing actuators for load
application


Refine the manufacturing process


Use independent testing to certify panel for use in
construction


Perform more detailed flood analysis




11/29/2013

25

Special Thanks


Jerry Horne at HPMI


Ron and Bob at SIPS Team USA


Dr. Abdullah, WHEEL Lab


Dr. Jung, Civil Engineering


Daniel Knapp, Dow Building Products


Dr. Ordonez, Faculty Advisor


Terry Shaw, Cummins, Project Advisor

11/29/2013

26

???Questions???

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27

Flood Resistance Testing


Testing:


Adhesive bond


Connection leakage


Panel strength


Results:


Filled
to
3.5 feet (218
psf
)


No leaking through
connection


No deflection


No signs of moisture inside
panels



11/29/2013

28

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29

Sample Calculations

11/29/2013

30


c.l
7.419
10
3

lbf
ft
2


Allowable Compressive Stress of the wall
panel
Bending stress of wall along length of house

b.l
M
max.L
y
c

I
367.946
lbf
ft
2



Bending stress of wall along width of house

b.w
M
max.W
y
c

I
525.637
lbf
ft
2



Found using the compressive
strength of each material multiplied
by its area fraction of the wall panel,
then summed.

Stresses experienced by the wall panel on the
cross-section perpendicular to the f orce along the
length.

p.l
F
R
A
p.l
291.429
lbf
ft
2



Stresses experienced by the wall panel on the
cross-section perpendicular to the f orce along the
length.

p.w
F
R
A
p.w
204
lbf
ft
2



Nominal stress in the wall panel
under static design load of 120
psf

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31