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Stranger Things: Building Materials of the Future

Wednesday, May 17, 2017 2:00 to 3:15 pm

Panelists

Melissa Lapsa, Oak Ridge National Laboratory (ORNL)

Tom Culp, PhD Birchpoint Consulting Achilles Karagiozis, PhD Owens Corning

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Melissa Lapsa ORNL

Building Envelope: 5.81 Quads

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The commercial building envelope is the primary determinant of the amount of energy required to heat, cool,

and ventilate a building

Barriers Identified for Envelope Technologies

Cost: uncertainties, high first costs, ROI hurdles

Supply issues: product fragility, availability, volume

Installation issues: workforce training, complex systems, quality control

Decision culture: resistance to new products, risk averse, code minimum culture

Information gap: real world case studies, data on long-term performance, communicating effectively

Strange Things. Innovations for Windows

Transparent Thermal Insulation Material

ORNL/VELUX collaboration

No use of supercritical drying (a costly method)

Potential for scale up Low cost

Thermally Insulative Window Applied Film

New! ARPA-E funded Developing transparent

thermally insulative applied films

Transparent and mechanically strong

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Strange Things Innovations for Building Envelope Systems

Modified Atmosphere Insulation (MAI) ORNL/NanoPore/Firestone collaboration: new composite foam-MAI

insulation board Measured R23.8 within 2-inches vs R6/in for existing insulation Projected MAI cost at large-scale production (1% of commercial roof

insulation material market share): $1.98/ft2 MAI composite board : $2.37/ft2 (vs. $1.70/ft2 for 4 regular polyiso board) Cost offsets : dual function as a coverboard, lower shipping and storage

costs

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1-inch MAI panels being carried into polyisocyanurate production line.

Finished board; 2-inch overall thickness with MAI panels completely

encapsulated. MAI cores surrounded by polyiso foam

Strange Things Architectural Precast Insulated Panels

30% Faster production of complex molds

50% Lighter panels

50% Higher thermal performance

Cost neutral

2 : 2 : 3

Concrete wythe

XPS insulation

Concrete density = 144 pcf Panel weight = 60 psf

Baseline

1 : 4 : 1

Concrete density = 100 pcf Panel weight = 25 psf

New Design

.3D Printed Mold

Building Elevation

Cornice

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Cornice Cross Section

3D Printing CNC Finishing Current Assembly Process

3D Printed Mold Prototype

Courtesy of THERMWOOD

Tom Culp Birchpoint Consulting

INNOVATIONS IN WINDOWS AND WINDOW ATTACHMENTS

THOMAS CULP, PH.D.

BETTER BUILDINGS SUMMIT

MAY 17, 2017

STRANGER THINGS: BUILDING MATERIALS OF THE FUTURE

TOPICS

Window Technology: What is the Latest & Greatest?

Window Technology: Coming Soon?

Window Attachments

NANOTECHNOLOGY

LOW-E COATED GLASS

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LOW-E GLASS Low Emissivity coatings Transparent, microscopic coating which

reflects infrared heat. Reduces building energy usage by up to 25% by

reducing radiative heat loss. Reduces overall U-factor

(lower U-factor = more insulating) Can be designed to also control solar heat gain.

Heat

Silver

Silver

Silver

10 nm = 0.00000001 m

Triple Silver Low-E Coating

Glass Substrate

STATE OF THE ART - GLAZING Triple silver or even quad silver low-e coatings that

maximize visible light (VT) and minimize solar heat gain (SHGC) SHGC < 0.25 with VT > 60% along with the low U-factor

Triple glazing with low-e glass and either argon or krypton but still slow adoption

Roomside (4th surface) low-e coatings in double glazing Durable low-e coating based on either fluorine-doped tin oxide or

indium tin oxide (ITO) that can be used exposed to the room.

Uc = 0.20 Btu/hrft2F with argon

Uc = 0.18 Btu/hrft2F with argon

Traditional Low-e

Durable Low-e

or (0.12 with two low-e coatings)

STATE OF THE ART - FRAMING Over 90% of commercial buildings use aluminum framing

Structural performance Durability Wide spans with narrow sight lines Design flexibility Recyclability / sustainability

However, unbroken aluminum frames have high thermal conductivity.

Solution: introduce thermal barriers Low conductivity material, but maintain structural performance Polyurethane and polyamide based systems

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STATE OF THE ART - FRAMING Double thermal barriers Wider thermal barriers Incorporation of composite materials New foam materials

Courtesy Azon, Technoform

DYNAMIC GLAZING Dynamic glazing: products that can reversibly change their optical

properties (SHGC, VT) Electrochromic in response to electrical voltage Thermochromic in response to temperature Photochromic in response to direct sunlight

Problem with traditional glazing: lower SHGC reduces cooling load higher SHGC reduces heating load higher VT can help daylighting lower VT helps glare / visual comfort

Static glazing forces a compromise to be made. Dynamic glazing allows SHGC and VT to be changed throughout the

day and season to optimize energy efficiency, peak loads, and daylighting/glare. 19

ELECTROCHROMIC DYNAMIC GLAZING Tungsten oxide based ceramic thin film low-e coating that changes

absorption in response to DC voltage.

SHGC range 0.09 0.47, VT range 0.02 0.62 Controls: photosensor, occupancy, time of day / year, manual

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DYNAMIC GLAZING EXAMPLES

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Courtesy of SAGE Electrochromics

DYNAMIC GLAZING EXAMPLES

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Courtesy of SAGE Electrochromics

BUILDING INTEGRATED PHOTOVOLTAICS (BIPV)

PV can be integrated into more than just rooftop panels Opaque areas, spandrel, dry screen Vision areas, overhead glazing Sun shades

Rooftop area can be very limited (tall buildings, mechanical equipment, etc)

South-facing vertical surfaces can provide 72% output of rooftop arrays

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BIPV OPAQUE AREAS AND SUNSHADES

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Courtesy of BISEM, Kawneer, Schuco

BIPV OVERHEAD GLAZING, VISION AREA

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Courtesy of Hydro, Schuco, TSNergy

DAYLIGHT REDIRECTING Micro-prismatic films applied to clerestory windows to bring

daylight deeper into the space.

80% of incident light redirected upwards

Other approaches: light shelves, daylight louvers

Courtesy 3M Films

WINDOW TECHNOLOGY COMING SOON?

VACUUM INSULATION

Courtesy Dow Corning

~ R32 per inch

If punctured, still R8 per inch due to fumed silica core (similar to basic level aerogel)

CAN WE DO THE SAME IN GLASS? VACUUM GLAZING With vacuum + low-e coating, greatly reduces conduction,

convection, and radiative heat loss.

4 mm glass

0.3 mm vacuum

edge seal

support pillars

low-e coating

Uc ~ 0.10 Btu/hr ft2 F vs. 0.24 for double pane low-e argon unit and 1.0 for single pane

Can eliminate condensation Thin profile (8.3 mm) replace single

glazing in existing buildings? Challenges:

Tempering for use as safety glazing in doors, hazardous locations

Weathering durability for use in windows Cost

CAN WE DO THE SAME IN GLASS? VACUUM GLAZING Likely first widespread application will be in doors for

refrigerated display cases. Already used in windows in Japan and Europe, but small

market share. As cost decreases, hope to see increased use in both high end

new windows and replacing single glazing in existing buildings.

Courtesy LandGlass / VIG Technologies

THIN TRIPLE GLAZING Why has adoption of triple glazing been slow?

THIN TRIPLE GLAZING Potential new solution: thin light triples Use thin (0.7 mm) nonstructural glass lite in center

to create triple glazing with reduced weight. Potential drop-in solution without major frame redesign. Center of glass U-factor

with 2 low-e coatings Uc ~ 0.15 with argon Uc ~ 0.12 with krypton

Over last 4 years, Thin glass price dropped 88% Krypton net price dropped 80%

First use likely in residential Courtesy of Steve Selkowitz, Lawrence Berkeley National Lab

WINDOW ATTACHMENTS AND EXISTING BUILDINGS

Existing frame and exterior single pane

Added low-e IG with hermetic seal

WHAT ABOUT EXISTING BUILDINGS? We often work hard on expensive new building

technology, then ignore the vast amount of energy wasted in existing buildings!

53% of commercial buildings have single glazing (2 billion ft2)

Over a 23 year period, only 6.7% replaced their windows

New cost-effective technologies to add low-e glazing to existing single pane windows

Low-e storm windows in residential buildings Low-e retrofit system or panels in commercial Case study in Philly has shown 40-60% reduced

energy use in perimeter zones, ~ 25% for overall building 34

courtesy of J.E. Berkowitz

WHAT ABOUT EXISTING BUILDINGS?

Low-E retrofit panels in multifamily, historic, commercial buildings where it may