EnergySmart Homes

EnergySmart HomesTMCost Neutral/Zero Energy

SafetyShield HomesTMTornado/Hurricane/Wildfire/Flood

EnergySmart Building Method, LLCZero Energy Home ComponentsZEH ComponentsPatented Envelope SystemDouble Wall Envelope (R54)Continuous Insulated BarrierComplete Air Tight SealBrackets Between WallsClosed Cell Spray FoamSolar Shingles & PanelsComputerized Smart HomeState-of-the-Art AppliancesGEO Thermal Heating & CoolingInsulated Window TreatmentsLow-E Windows (R11)Five Home Options Available

Zero Energy Home (ZEH)

ZEH & Tornado Package

ZEH & Hurricane Package

ZEH & Earthquake Package

ZEH & Wildfire Package

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EnergySmart Building MethodTM The main difference in construction of an EnergySmart Building Method TM house and a standard site-built house is the manufactured interior in conjunction with the patented EnergySmart Building Envelope System TM consisting of a second exterior wall with closed cell spray polyurethane foam (SPF) insulation between the two walls held together by brackets and across the ceiling trusses achieving a minimum R-54 insulation factor and eliminating 30% of the homes energy loss that is normally lost through the walls, windows and ceiling.

The patented EnergySmart Building Method TM creates a brand new tier of state-of-the-art, hybrid, energy efficient smart homes for the residential housing industry that meet the DOE goals for cost-neutral, net-zero energy homes; and are significantly safer in tornados, hurricanes, earthquakes, wildfires and floods.

The EnergySmart Building Method TM uses the 20-25% cost difference between a site-built house and a manufactured/modular house to build in energy efficiency and safety.

The strategy is to use the approximately $30,000 to $37,500 cost difference based on a $150,000 site-built house to pay for the addition of the patented building envelope system and energy efficient technologies and materials in EnergySmart Homes TM and create a hybrid, cost-neutral, net-zero energy home today instead of 20 years from now.

Tornados & HurricanesHigh-tech Building Envelope SystemEconomic & Human CostEffective Design to lower RiskWind Science and Engineering Research CenterHigh-tech Building Envelope SystemBenefit: Safer in Tornados & HurricanesThe entire double wall building envelope system is basically glued together and cured to form one continuous 9 thick structure that surrounds the house; walls and ceilings. The double walls also have brackets between them (patented claim) and when glued together makes them impossible to pull apart. When combined with existing hurricane anchoring systems and reinforcement products, these homes should be some of the safest available in tornados or hurricanes.

Imagine a steel box with cutouts for windows and doors turned upside down and anchored to the foundation; it would be virtually impossible to tear it apart.

The tornado models would come with the patented EnergySmart Building Envelope SystemTM, anchors & tie-downs, steel window shutters, steel entry doors, reinforced garage doors, potential wall reinforcements, and barometric pressure alarm

The Hurricane models would consist of the tornado model plus door seals to a height of three feet and escape skylight in the roof

Benefit: Flood protectionThe closed cell spray foam insulation bonds to everything it touches forming a water tight seal in the building envelope system structure that surrounds the house and is impervious up to the bottom of the window openings (requires sealing the doors to a height of approximately 3 feet).

Tornado/Hurricane/Wildfire/FloodAll Packages are Zero Energy HomesTornado PackagePatented Envelope SystemAnchors & Tie-downsSteel window shuttersSteel entry doorsReinforced garage doorsPotential wall reinforcementsBarometric pressure alarmHurricane PackageTornado Package Door Seals 3ft HeightSkylight hatchWildfire PackagePatented Envelope SystemMetal Roof Fireproof sidingSteel doors & shuttersSpray foam insulationCommercial fire retardantEarthquake PackagePatented Envelope SystemAnchors & Tie-downsFlood Plain ProtectionPatented Envelope SystemDoor Seals 3ft HeightEconomic CostTornadoes were the costliest natural catastrophes in the U.S. in 2011 - the year of Joplin and Tuscaloosa - with an estimated $47 billion in overall economic damage, and insured losses of $26 billion.

Tropical storms topped the natural disaster list in 2012 because of Hurricane Sandy. But even in a relatively quiet tornado year, economic losses from severe thunderstorms reached $28 billion in 2012 and insured losses $14 billion.

The Moore, Oklahoma tornado on May 20, and associated storms, could cost up to $5 billion in insured losses, disaster modeling company Eqecat has estimated, making it the second costliest tornado outbreak on record after Tuscaloosa.

Human CostTornadoesThe United States averages about 1000 recorded tornadoes every year resulting in an average of 1,500 injuries and 80 deaths. (www.tornadoproject.com) (www.nssl.noaa.gov)

ThunderstormsThe United States averages about 100,000 recorded thunderstorms every year resulting in an average of 31 deaths caused by wind. (www.pathnet.org) (www.gweather.com)

HurricanesThe United States averages about two hurricanes per year that actually strike the coast of the U.S. resulting in approximately 60 injuries and 17 deaths. ( www.aoml.noaa.gov) (www.loep.state.la.us)

Shelters Since 1980, approximately 20,000-30,000 shelters have been built. (www.fema.gov)Human CostFlorida leads the country in deaths calculated per mile a tornado races along the ground, followed by Tennessee, North Carolina, Ohio and Alabama, according to an analysis of the past three decades by the federal Southeast Regional Climate Center at the University of North Carolina.

Along with Florida, Dixie Alley including Arkansas, Louisiana, Alabama, Mississippi, Georgia, Tennessee, Kentucky, western parts of the Carolinas is where "more people die from tornadoes" than anywhere else in the world.

Florida tends to get tornadoes more in the winter, while the Southeast tornado season is February through April. The Midwest generally sees them in the spring and summer.

In 2012 there were seven tornadoes that killed 35 people; 32 of them in the Southeast, including 16 in Arkansas and 11 in Mississippi.

Designed for SafetyThe EnergySmart Building Envelope System (ESBES) in combination with a proper anchoring system and specific other reinforcement products would easily be one of the safest homes in a tornado or hurricane from the standpoint of wind damage and destruction of the home. The ESBES construction method results in a nine (9) inch thick solid wall and ceiling that surrounds the living area (like an upside down steel box), and is anchored to the foundation making it highly improbable that the structure could be torn apart by tornado or hurricane force winds.

The envelope is constructed of two 2 x 4 walls held together by brackets along the length of the wall and from the bottom to the top of the walls (patent claim awarded for bracket use), is nine (9) inches thick, and filled with closed-cell spray foam that hardens and glues everything together. Designed for SafetyOne measure of safety is whether the house will maintain its integrity and still be standing intact after the tornado or hurricane has passed, and the other measure of safety is the structures ability to impede flying missiles that can penetrate the walls and do damage or injury to the contents or occupants.

Here we look at tests done to determine the safest construction methods to prevent flying missiles from penetrating the structure. Looking at the range of results from tests run at the Wind Science and Engineering Research Center we can estimate where the EnergySmart Building Envelope System would test out.

The range of tested material results run from a threshold missile speed of 22mph (worst result) to 162mph (best result).

Designed for SafetyThe least safe wall is a 2 x 4 Standard Residential Stud Wall with OSB Sheathing, Insulation & 1/2-inch Gypsum Board (Fiber-cement Board Sided Stud Wall) with a threshold missile speed of 22mph (missile penetrates wall at 22mph).

The safest wall is a 4 in. thick pea-gravel concrete wall with #4 rebar reinforcement 12 inch on-center each way at 162mph; and a 6 inch Reinforced Masonry Unit (CMU) reinforced with concrete and #4 rebar in every cell with 8-gage truss horizontal reinforcement every other course, that tests out at a threshold missile speed of 130mph. Designed for SafetyStud Walls (one 2 x 4 wall) with Polystyrene Infill using 4 layers of in. CD grade plywood with two layers of energy absorbing polystyrene as inserts achieved a threshold rating of 105mph.

The EnergySmart Building Envelope System is comprised of two 2 x 4 walls held together by brackets along the length of the wall and from the bottom to the top of the walls, is 9 inches thick, and filled with closed-cell spray foam that hardens and glues everything together.

The wall should achieve an approximate threshold missile speed rating in the range of 110mph to 115mph and if a reinforcing material such as plywood or metal or properly formulated polyurethane sheet were included, it could potentially exceed 130 mph. The FEMA safe room requirement is to pass the test at 100 mph.

Designed for SafetySummaryThe safety of homes built using the EnergySmart Building Envelope SystemTM are in the range of solid reinforced concrete and/or reinforced masonry unit constructed homes but have the added advantage of:

Designed to be zero energy smart homesFree utilities for life (no utility bills)Cost the same as conventional site-built homesCost less than reinforced concrete homesCost less than reinforced masonry homesSafer in tornados and hurricanesSafer in floods or flooding from hurricanesSafer in wildfires with a metal roof packageSafer in earthquakes

Threshold Missile Speed RatingIts not our intention to have the best rated wall construction for threshold missile speed.

What we do offer is a home that is significantly safer than any conventional stick-built home and approaches the safety of a home built using reinforced concrete with horizontal and vertical rebar in it.

EnergySmart HomesTM are the best option in geographic areas that are prone to tornados and hurricanes when you factor in all considerations due to their ability to withstand severe high winds and their estimated high threshold missile speed rating, low cost, and energy efficiency.

Threshold Missile Speed Rating

Threshold Missile Speed Rating

EnergySmart HomesTMEnergySmart HomesTM vs. Site-Built HomesNet-Zero Energy Homes ComponentsEnergySmart Building ConceptEnergySmart Home vs Site-Built HomeEnergySmart HomeSite-Built HomeNo utility bills for life

EnergySmart Building Envelope SystemTM

Solar Panels or Shingles

Closed cell SPF Insulation

It's a Smart Home

Many Energy Efficient Technologies

Potential $10,000 Rebate for Homebuyer

Purchase Price = $150,000

$1,800 to $2,400 utility bills/year

Standard Building Method

No Solar Panels or Shingles

No closed cell SPF Insulation

It's Not a Smart Home

Some Energy Efficient Technologies

No Rebate for Homebuyer

Purchase Price = $150,000

High-tech Building Envelope SystemBenefit: Results in Air-tight Seal

The closed cell spray foam insulation bonds to everything it touches forming an air tight seal in the building envelope system structure that surrounds the house and makes it possible to achieve the highest energy efficiency.

Benefit: Results in Increased Strength

The closed cell spray foam insulation bonds to everything it touches forming an solid core of cured foam and a reinforced building envelope system structure that surrounds the house and makes it resistant to tornados, hurricanes, earthquakes, & wildfires.

Net-Zero Energy HomesEnergy Efficiency & Smart Home TechnologiesOptimize available energy efficient technologies to achieve Net-Zero EnergySolar PanelsSpray Polyurethane Foam (SPF) InsulationEnergySmart Building Envelope SystemTMHome energy management systemInnovative LED lighting brightens and dims according to outside brightnessTime-use management of appliances with wireless controls Use of hybrid electric heat pumps for hot waterMicro Wind TurbinesTOOLBASE lists over 204 materials, products and methods that contribute toward energy efficiency in a house

Add Smart Home technologyComputer control of security, lighting, video systems, audio systemsWhirlpool has also set a goal to make its appliances "smart" by 2015Smart appliances that generate lists, place online orders and send text messages

Net-Zero Energy HomesEnergy Efficiency & Smart Home TechnologiesEnergySmart Building ConceptCost-Neutral HomesThe EnergySmart Building MethodTM and Concept develops a brand new tier of hybrid state-of-the-art energy efficient homes for the residential housing market that meet the DOE goals for cost-neutral, net-zero energy homes.

These homes will compete with standard site-built homes that have none of the features and enhancements of the EnergySmart HomesTM for the same cost.

The EnergySmart HomesTM use the $30-$37,500 difference between the cost of a site-built house and a manufactured house to pay for the addition of energy efficient technologies and materials in the new homes, creating cost-neutral, net-zero energy homes today instead of 20 years from now.EnergySmart Building Concept Manufactured Housing IndustryVP of Marketing for Major Manufactured Housing Company

The HUD code allows for the use of materials not commonly found in site constructed homes. These are typically lower cost finish material and doors and windows. Cabinets may have a paper veneer, wall panels will be individually wrapped gypsum, carpet may be 18oz, exterior doors shorter, and the list goes on. So once you establish an even base of materials for the two building techniques any savings driven will be by the efficiencies inherent in the manufacturing process when compared to the relative inefficiencies in site construction. These efficiencies will be captured in labor savings and better material use (less waste and damage).

If you are comparing the construction techniques against scattered lot construction then the site-built efficiencies drop dramatically. Also as you move up the price spectrum to higher end semi-custom homes site efficiencies drop even more. So, if you are comparing a home on a basement, in a market where labor is high and the site is a one-off then I would say 20% savings could be realized.EnergySmart Building Concept Manufactured Housing IndustryThe EnergySmart Building MethodTM homes seem to fit this definition: move up the price spectrum to higher end semi-custom homes and home on a basement, in a market where labor is high and the site is a one-off. Kevin Flaherty indicated there were additional construction and material decisions that could drive the final cost difference up and certain site-built markets where the difference wouldnt be as great, but the 20% figure is based on comparable materials being used in both the manufactured and site-built homes in the type of market stated above.

The federal standards regulate manufactured housing design and construction, strength and durability, transportability, fire resistance, energy efficiency and quality. The HUD Code also sets performance standards for the heating, plumbing, air-conditioning, thermal and electrical systems. It is the only federally-regulated national building code. EnergySmart Building Concept Manufactured Housing IndustryIn the case of EnergySmart HomesTM, you would mandate the quality requirements and specify ALL safety product content in the homes.Why would the MHI want to contract with you to build these homes?$15 to $30 million in new sales each year per manufacturerThe industry has been hit hard by the economy400k homes per year down to 48k last yearLoans for manufactured homes are scarce Rebates & special FHA loans may be made availableThey have open capacity of 25% or more (25k/yr)Overcomes reputation of not being safe in the event of a tornado/hurricaneThey can ramp up their capacity to 100k/yr quicklyThis opens a new housing market for themThese hybrid homes compete with conventional housing marketsThe EnergySmart Building MethodTM and Concept canOvercome problems with local building ordinancesConvert a perception of being mobile to permanentOvercome problems with lenders & financing185 factories that employ 100-200 people when in full production would create thousands of jobs17 Patent Claims Awarded (Patent #8590262)Results in a Cost-Neutral, Zero Energy HomeA method of constructing an improved energy efficient buildingThe Building Envelope System using pre-fabricated interiorsAdhering the spray foam insulation to the double walls and ceiling trusses in the building envelope systemFilling the spaces between the double walls with spray foam insulationIncreased structural strength of the buildingIncreased resistance to damage from tornadoes or hurricanesIncreased resistance to leakage due to floodingComprises a fire-retardant barrier around the houseComprises a sound absorbent barrier around the houseCreates an air-tight seal and highest possible energy efficiencyBrackets that span the spaces between the outer walls and the partition walls; along the length of the wall and from the top to the bottom; patent claim awarded for use of brackets between wallsSurrounding the living area of the building with a continuous layer of the insulation material bonded to the double-wall building envelope system and ceiling trusses for safety and energy efficiency resulting in a complete encapsulation of the living areaBusiness StrategyPotential Market SalesEntry into the MarketPotential Market SalesMcKinsey & CompanyFeature: 100,000 Green Advocate Buyers TodayBenefit: $14 billion Market Already Exists

The National Association of Home Builders Center, National Renewable Energy Laboratory, and US Department of EnergyFeature: Demand for 125,000 homes by 2025Benefit: $18 billion yearly marketFeature: Demand for 325,000 homes by 2030Benefit: $48 billion yearly market

FEMA60 million homes nationwide are built in geographic areas prone to tornados/hurricanes/wildfires

Marketing OptionsBuild Your Own Brand of EnergySmart ZEH Safe HomesTM; Convert some of your existing home designs and create multiple package options for each house!

ZEH Package House Design #1Add the patented EnergySmart Building Envelope SystemTMAdd selected ZEH componentsSolar Shingles & Panels, Computerized Smart Home, State-of-the-Art Appliances, GEO Thermal Heating & Cooling, Insulated Window Treatments, Low-E Windows (R11)

Tornado Package House Design #1ZEH Package, Anchors & Tie-downs, Steel Window Shutters, Steel Entry Doors, Reinforced Garage Doors, Potential Wall Reinforcements, Barometric Pressure Alarm

Hurricane Package House Design #1Tornado Package, Door Seals 3ft Height, Skylight hatch

Earthquake Package House Design #1ZEH Package, Anchors & Tie-downs

Wildfire Package House Design #1ZEH Package, Metal Roof , Fire Resistant Siding, Steel Doors & Shutters, Spray Foam Insulation with Commercial Grade Fire Retardant

Floodplain Package House Design #1ZEH PackageDoor Seals 3ft Height

ConclusionThese are patent protected homesThe projected ZEH market in 2035 is 325,000 unitsThe highest energy efficiency on the marketThe only cost-neutral, zero energy homesSafer in tornados, hurricanes, earthquakes, wildfires, and floodsThe current Tornado/Hurricane market is 1,000,000 units (est.)The projected Earthquake & Wildfire home market is 1,000,000 units (est.)For any Manufactured Housing Companies in theses target areasLow cost, low risk entry into the marketSales potential for homes is 15k to 60k units/yearThe ROI is anywhere from $450M to $9B/year in salesAt risk investment to build a prototype is approximately $30,000Schedule AU.S. Department of EnergyEnergy Efficiency & Renewable EnergyBuilding Technologies ProgramCase Study:Nelson ConstructionHamilton Way | Farmington, CT Design-stage computer analysis estimated that 18.5% of the energy-efficiency savings could be achieved by reducing air infiltration. Closed-cell foam spray insulation.Case Study:Rural Development, Inc.Wisdom Way Solar Village | Greenfield, MAA unique feature of the homes is their double-walled construction. The exterior 2x4 16-inch-on-center framed wall is built first; it is sheathed on the exterior side with OSB, but no interior gypsum. Brackets are used at various points along the wall to maintain the integrity of the double wall spacing.Double Wall Construction Cost ComparisonChandler Design-Build919-812-7478Michael@ChandlerDesignBuild.com Mailing address - 3249 Henderson Field Rd. Mebane NC 27302Office address 1610 Jordan Drive, Saxapahaw NC 27340Increasing attention is being drawn to double wall construction as a cost-effective, high R-value alternative to competing high R-value systems such as ICFs, SIPs, AAC, ThermaSteel, etcetera.

Schedule AAdvantages of double wall construction are:Simplified wiring and plumbing due to wide open access prior to insulation, especially important when smart home wiring requires holding low voltage wiring well away from line voltage. The embodied energy and global warming impact of the double wall system also compares favorably with that of the concrete and foam in ICFs, Rastra and SIPs and the concrete and aluminum in AAC walls. These walls, including exterior OSB, are framed off-site and all scrap diverted to an I-joist plant and the walls for a typical house go up in a day. Were generally dried in with tar paper on the roof in two weeks.Whole wall Steady state R-value of a 10 AAC is R-12, 10 Rastra is R-16.5, 9 ICF is R-20, 6.5 SIP is R-23. We can expect a 12 double wall assembly with R-46 cellulose or JM Spider formaldehyde-free micro-filament fiberglass insulation in a thermally broken assembly to be well above any of these.

Schedule ABut most significantly the cost of double wall per R-value delivered is very favorable. Our wall panel quote on a recent 2,474 heated sf home was $12,810 total, $5 / square foot of heated floor area for double 2x4 construction (and $6.15 w/ 2x6 exterior walls needed with 2 of exterior foam on the foundation). The total cost for the JM Spider R-46 formaldehyde-free micro-filament fiberglass insulation was $1.30 per SF and this was done in a day and a half. So the wall cost for our 2,500 sf house was $16,000 with the 2x4 exterior walls (and $18,500 w/ 2x6 ext. walls). By comparison the panel quote for a similar house with energy framed 2x6 walls was $3.40 / sf and the 5 R-23 spider insulation quote was $0.70 so the up-charge to go from 2x6 w/ R-23 to 12 dbl 2x4 walls w/ R-46 would be from $10,250 to $16,000. At $5,750 this is less than the up-charge for a solar water heater.http://chandlerdesignbuild.blogspot.com/2009/12/increasing-attention-is-being-drawn-to.htmlWoodcraft Building Inc.DOUBLE WALL CONSTRUCTIONTwo is better than one! By changing the typical single 26 wall to double 24 walls you can not only adjust the R value of your wall, you can create a higher Whole Wall R value WWR. By adding the option of Advanced Framing, meaning the studs are on 24 centers rather than 16, you would use less lumber and more insulation. Wood has a much higher U value or lower R value, so using unnecessary lumber not only saves on your lumber bill, but it raises your insulation or R value too. On a typical home the roof trusses are on 24 centers so framing your wall on the same layout would line your wall studs directly under your roof trusses.http://www.woodcraftinc.com/tag/double-2x4-walls/

Schedule AU.S. Department of EnergyBuilding America Solution CenterBrackets connect the exterior wall to the interior wall. The EnergySmart Building Envelope System has the patent on using brackets to connect two walls together (Patent #8590262).How to Construct a Truss WallThe truss wall uses two sets of studs like the double-stud wall, but in this case the interior wall is the load-bearing wall. The exterior wall is attached at each stud and hangs cantilevered outside of the foundation wall, which frees up floor space compared to a traditional double-stud wall. The interior and exterior wall studs are aligned and connected with plywood gusset plates toward the top, middle, and bottom of each pair of studs, and a plywood cavity closure at the top and bottom of the stud cavities. These gussets and closures provide stability so that the walls can be further apart, allowing more room for insulation. The bottom edge of the exterior wall drops below the sill plate, providing space that can be filled with insulation along the exterior side of the rim joist, thus minimizing the thermal bridging that can otherwise occur through the rim joist.In this example a 2x4, 16-inch on-center interior load-bearing wall is connected to a 2x3, 16-inch on-center exterior nonbearing wall spaced to provide 11 inches of cavity width that is filled with cellulose insulation for a calculated whole-wall R value of R-36.5 or clear-wall value of R-40.5 (Straube and Smegal 2009). This wall, which is designed for climate zones 6 or higher, has a Class I vapor barrier of 6-mil polyethylene installed between the interior wall and the drywall. (For warmer climate zones, no vapor barrier should be installed.) Because of the location of the plastic in this wall assembly immediately behind the drywall, it will be perforated by electrical wiring and plumbing. If the wall is not air sealed at the drywall layer, warm moist air could get into the wall cavity through these perforations and condense on cooler outer framing. (See Straube and Smegal 2009 for more on moisture issues).

Schedule A

Figure 3 - This truss wall - consisting of a 2x4, 16-inch on-center interior load-bearing wall connected to a 2x3, 16-inch on-center exterior nonbearing wall with plywood gussets - is spaced to provide 11 inches of cavity width that is filled with cellulose insulation for a calculated whole-wall R-value of R-36.5 or clear-wall value of R-40.5

The EnergySmart Building Envelope System uses spray polyurethane foam which is much more energy efficient.Schedule A

Schedule B

Schedule B

Schedule B

Schedule B