Using Aerosol Sealant to Reduce Multifamily Envelope Leakage
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This presentation provides information on a field research project of an aerosol sealant used to reduce the leakage of existing and new construction multifamily units.
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Using Aerosol Sealant to Reduce Multifamily Envelope Leakage
- 1. Using a Aerosol Sealant to Reduce Multifamily Envelope Leakage Dave Bohac PE | Director of Research Ben Schoenbauer | Senior Research Engineer Jim Fitzgerald | Senior Building Analyst Center for Energy and Environment 2016 Energy Design Conference
- 2. Credit In accordance with the Department of Labor and Industry’s statute 326.0981, Subd. 11, “This educational offering is recognized by the Minnesota Department of Labor and Industry as satisfying 1.5 hours of credit toward Building Officials and Residential Contractors code /1 hour energy continuing education requirements.” For additional continuing education approvals, please see your credit tracking card.
- 3. Pg. 3 What We Do • Energy Program Design & Delivery • Engineering Services • Lending Center • Public Policy • Innovation Exchange • Research • Education and Outreach
- 4. Pg. 4 Multifamily Experience • Facility assessments of over 2,000 buildings in Minnesota • Completed over 20 research projects
- 5. Pg. 5 Current Multifamily Research Projects PROJECT ANTICIPATE FINDINGS • Condensing boiler optimization Early 2016 • Multifamily ventilation optimization Early 2016 • Multifamily aerosol envelope air sealing Mid 2016 • Indoor pool optimization Late 2016 • Demand controller recirculation loop Mid 2017 The Conservation Applied Research and Development (CARD) grant program is funded by MN ratepayers, and administered by the Minnesota Department of Commerce, Division of Energy Resources
- 6. Opportunity: • Existing. Thousands of leaky units – reduce air infiltration with limited or no added ventilation. • New Construction. Moderately tight with ventilation – seal to nearly eliminate air infiltration and air transfer.
- 7. Challenge: • Existing. No/difficult/costly access to distributed air leaks. 10% to 25% reduction is challenging. • New Construction. Single family approaches only recently starting to carry over to multifamily buildings.
- 8. Envelope Tightness Requirements: • Code. 1 to 3 story buildings must meet 3.0 ACH50 residential requirement. 4+ story buildings - typically use tight materials or assembly to meet prescriptive requirement – not whole envelope test. • Green Communities (MHFA). EPA ENERGY STAR for multifamily high rise = 0.3 cfm50/sf (4 – 8 ACH50). • No requirements prior to 2015.
- 9. Pg. 9 Envelope Aerosol Sealing • Pressurize apartment • Spray air sealing fog • Sealant particles build up on gaps as they flow through the leaks Similar to process used for aerosol duct sealing
- 10. How does it do that? No, really? (animation video here) Sealant is GREEN Guard Gold Certified for use in California school and health care facilities
- 11. Benefits: • Reduced air infiltration energy costs • Reduced odor transfer & improved IAQ • Improved comfort • Reduced noise transmission • Simultaneous air leakage testing documents results • Potential savings for avoided conventional air sealing (?)
- 12. Pg. 12 Study Objectives: Demonstrate sealing capability and evaluate commercialization • Refine sealing technique – measure leakage and noise transmission reduction & identify sealing locations • How to incorporate into sealing strategy – preseal “large” leaks and protect horizontal surfaces as necessary • Time estimates • Model energy savings and effect on ventilation 1. Sealed 18 units in 3 new construction buildings 2. Sealed 9 units in 3 existing buildings
- 13. Pg. 13 Aerosol Sealing Process: Design Visit – Before Construction 1. Identify air tightness goal 2. Describe aerosol sealing process 3. Review air barrier details 4. Specify that leaks with gap width > 3/8” must be sealed or reduced to 3/8” 5. Determine when aerosol sealing will be applied in construction process 6. Discuss “conventional” sealing that may not be necessary (consider fire code) This is ideal process
- 14. Pg. 14 Aerosol Sealing Process: All In One Visit 1. Walk thru to identify pre-sealing & protection requirements (prior to sealing visit?) 2. Pre-seal large gaps & temporary sealing as necessary 3. Site work prep – cover horizontal surfaces 4. Set up sealing equipment 5. Perform sealing 6. Remove coverings 7. Clean surfaces (if necessary) 8. Post-sealing air leakage test 9. Air leakage test when unit finished?
- 15. Pg. 15 Site Work Prep: pre-seal wide gaps Sprinkler head Plumbing penetration
- 16. Pg. 16 Site Work Prep: pre-seal wide gaps Range electric line Low-voltage wiring
- 17. Pg. 17 Site Work Prep: pre-seal wide gaps AC Line set Duct – narrow enough to leave?
- 18. Pg. 18 Site Work Prep: pre-seal wide gaps Construction Plumbing Electrical Mechanical Floor wall connection Showerhead penetration Range plug Line sets for HVAC Sprinkler penetration Sink penetrations Electric baseboards Vent duct penetrations Waste line penetrations Low voltage wiring Fresh air duct penetration Clothes washer connections Additional wiring penetrations Combustion and exhaust air penetrations Toilet water connection PTAC wall penetration Kitchen water connection Gas line penetrations (range, HVAC, laundry) 1 to 2 hours/unit
- 19. Pg. 19 Site Work Prep: baseboards Seal before quarter round, caulk after? What about leaky wood floors?
- 20. Pg. 20 Site Work Prep: temporary sealing Exterior doors Combustion ventsExhaust fan ducts Plumbing penetrations Fill traps or cover waste line openings Shower handles
- 21. Pg. 21 Site Work Prep: temporary sealing Construction Plumbing Electrical Mechanical Door frames Bathroom handles Intercom Bath fan Floors (i.e. finished hardwood) Drains Low voltage outlets Kitchen fan Exterior doors (not used for fan frame) Waste lines Smoke detectors Additional ventilation Large holes/openings in the envelope Alarms Combustion and exhaust air Windows (leaky) Sprinkler heads PTAC openings Outdoor air intakes Forced air registers Forced air returns
- 22. Pg. 22 Site Work Prep: cover horizontal surfaces
- 23. Pg. 23 Site Work Prep: cover horizontal surfaces Ideal: drywall mud/tape no other finishes (bare floor better) Not ideal: ready for occupancy
- 24. Pg. 24 Site Work Prep: cover horizontal surfaces Construction Plumbing Electrical Mechanical Floors Tub or shower surrounds and floors Ceiling Fans Top surface of baseboard heating Window sills Toilets, sinks, other bathroom pieces Light switches Window meeting rail and muntins Plumbing fixtures Light fixtures Door tops and hardware Sprinkler heads Top surface of baseboards, trims, and molding Horizontal surfaces of cabinets and built-ins Temporary seals & covers: 3 to 7 hours/unit
- 25. Pg. 25 Site Work: Set-up, Seal & Breakdown • Blower door and nozzles • 100Pa pressurization • ~ 90% RH maintained • Open windows & purge 6 to 7 hours/unit Remove Covers & Pack-up • Care to not disturb seals • Minimal clean-up 1.5 to 3.5 hours
- 26. Pg. 26 Site Work Prep: how long does it take? 14 – 22 hours: still learning
- 27. Pg. 27 Site Work Prep: reduce time Opportunities to reduce labor time • Pre-sealing: new construction – GC or sub completes • Unit preparation: select time during construction when • Minimum horizontal surfaces to protect • Leaks are accessible • Seals will be durable • Sealing time: new generation of more portable equipment is being developed & stop when no longer cost effective • Breakdown/clean-up: minimize surfaces to cover and better positioning of spray nozzles
- 30. Pg. 30 Site Work Prep: black light photos
- 31. Pg. 31 Leakage Reduced Over Injection Period ACH50 pre: 2.0 – 2.9, post: 0.2 – 0.7; 71% to 94% reduction New construction Floor area: 900 to 1,300sf
- 32. Pg. 32 Sealing Rate Stop time?
- 33. Pg. 33 Leakage Reduced Over Injection Period ACH50 pre: 7.1 – 8.4, post: 0.9 – 1.4; 82% to 89% reduction New construction Floor area: 350 to 420sf Sealed 4 in one day
- 34. Pg. 34 Leakage Reduced Over Injection Period ACH50 pre: 12.0 – 17.2, post: 1.4 – 10.5; 39% to 88% reduction Existing units Floor area: 230 to 250sf Sealed 4 in one day Large leak behind kitchen cabinet
- 35. Pg. 35 Leakage Results: 18 New Construction Units Average leakage: pre= 3.9 ACH50, post= 0.7 ACH50 54% to 95% below code requirement, average= 77% 1-3 story code requirement
- 36. Pg. 36 Leakage Results: New Construction Reduction: 67% to 94%, average = 81%
- 37. Pg. 37 Leakage Results: 9 Existing Units 1-3 story code requirement Average leakage: pre= 14.1 ACH50, post= 4.8 ACH50 6 of 9 within 15% of new construction code requirement
- 38. Pg. 38 Leakage Results: Existing Units Reduction: 39% to 89%, average = 68%
- 39. Pg. 39 Reduced Noise Transmission • Sound transmission testing was conducted in a MF building in NY • Protocol based on ASTM E90 • Seal was an effective sound barrier between 800-5000 Hz • Human voice frequency falls between 300-3000 HZ • Helps to meet Building Code (IBC) requirement of 50 STC
- 40. Pg. 40 Energy & Ventilation Modeling • EnergyPlus model: air flows computed from leakage paths and wind/stack/ventilation imbalance • Three levels of tightness: • 9.5 ACH50 (leaky/existing) • 3.0 ACH50 (new code) • 0.6 ACH50 (aerosol sealed) • Ventilation systems (0.35ach = 70cfm rqd): • balanced • exhaust only • supply = half of exhaust • none 6 story, 4 units/floor 1,200sf/unit Leakage Distribution Exterior = 28% Hallway = 51% Adj Unit = 16% Ceiling = 5%
- 41. Pg. 41 Energy & Ventilation Modeling New Construction Therm/yr 12 17 27 26 $/yr $7 $10 $16 $15 4% 8% 11% 18%
- 42. Pg. 42 Energy & Ventilation Modeling Existing Units Therm/yr 41 56 67 68 $/yr $24 $33 $39 $39 11% 17% 19% 25%
- 43. Pg. 43 Energy & Ventilation Modeling New Construction Outside Air Ventilation & Infiltration 0.6 ACH50 = 96 cfm50; depressurization???
- 44. Pg. 44 Energy & Ventilation Modeling New Construction Flow From Adjacent Apartment 68 to 80% Reduction
- 45. Pg. 45 Energy & Ventilation Modeling New Construction Flow From Corridor
- 46. Pg. 46 Energy & Ventilation Modeling Existing Units Outside Air Ventilation & Infiltration
- 47. Pg. 47 Energy & Ventilation Modeling Existing Units Flow From Adjacent Apartment 85% to 87% Reduction
- 48. Pg. 48 Air Sealing at Lower Cost? Aerosol • Prep • Sealing process • Simultaneous air leakage testing ensures results Manual air sealing i.e. caulking/foaming • Architectural specification • Labor • Air leakage test => Uncertain results Vs.
- 49. Pg. 49 Conclusions • Not a solution for large air leak gaps • When aerosol envelope sealing can be used • New construction • Rehab • Change in occupancy (higher cost) • New construction • 81% reduction & 77% below code • Heating savings= 27 therms/yr, 11% • 80% reduction in flows from adjacent units • Existing units • 68% reduction & 6 of 9 within 15% new code • Heating savings= 67 therms/yr, 19% • 85% reduction in flows from adjacent units • Balanced ventilation is crucial for new construction, exhaust or supply OK for existing • Can you eliminate some “conventional” sealing? If not, too costly?
Hinweis der Redaktion
- I’ve been at the Center for Energy and Environment for 25 years and am currently the Director of Research. But instead of talking about my background I’d like to say a bit about our organization. CEE is a nonprofit that is involved in a variety of energy efficiency services including program design & delivery; engineering services; research; education & outreach; public policy; and loans. For example, the One-Stop Efficiency Shop lighting program has worked with over 10k businesses resulting in a reduction of over 100 MW of demand We have served over 25,000 residents through our single and MF programs Our research tends to focus on emerging technologies or services to improve our programs. For example, we ran the sound insulation program to treat about 13,000 house around the Minneapolis airport and through that program came our interest in combustion safety testing of water heaters and furnaces – and out of that grew our interest in power and direct vent combination systems as an alternative to natural draft appliances. That was also an interest of the LIWX agencies in our area who were installing high efficiency furnaces and then had to deal with orphan water heaters that often had a spillage problem, but they could only replace these with minimum efficiency power-vent water heaters. The Innovation Exchange is the research and dissemination arm of the Center for Energy and Environment, creating opportunities to communicate research and knowledge to energy and building experts through… webinars, forums, blogs posts, and social media as well as data visualizations and other tools that help make information more applicable. CEE has originated more than 25,000 loans resulting in over $190 million in community rehabilitation
- CEE has been involved in MF since early 1980s Started w research on boiler controls and identification of other opportunities (study published 1984) Ran programs in MN, also involved for a while with Focus on Energy.
- We are involved in CARD grant research funded through the Division of Energy Resources. We’re also involved with a benchmarking pilot, through a company called EnergyScoreCards. We have about 500 MF bldgs throughout the state enrolled in this. The idea is we’ll see if providing MF building owners and managers with a benchmark of their energy usage, compared to similar buildings, will provide energy savings in itself, sort of like an OPOWER for MF buildings.
- Reduced stack effect Possibly an expedited process Reduced noise transfer Reduced odor transfer/improved IAQ Increased comfort Increased energy efficiency
- Reduced stack effect Possibly an expedited process Reduced noise transfer Reduced odor transfer/improved IAQ Increased comfort Increased energy efficiency
- Reduced stack effect Possibly an expedited process Reduced noise transfer Reduced odor transfer/improved IAQ Increased comfort Increased energy efficiency
- Concept: A recently developed technology at UC Davis for -automating the envelope sealing process -process involves briefly pressurizing a building to normal testing pressures while applying an aerosol “fog” to the building interior. -As the air escapes through leaks in the exterior shell of the building (including leaks between apartments), the aerosolized sealant is transported to the leaks, and seals them as it tries to escape. -Existing blower door equipment is used to facilitate the sealing process as well as to provide real-time feedback and a permanent record of the sealing that is occurring. -This technology is thus capable of simultaneously measuring, locating, and sealing leaks in a building envelope (using aerosol particles has been successfully tested in the laboratory and demonstrated in full-scale applications. The aerosol envelope sealing e providing permanent documentation of the sealing process.)
- Reduced stack effect Possibly an expedited process Reduced noise transfer Reduced odor transfer/improved IAQ Increased comfort Increased energy efficiency
- 2 near term applications: new construciton, post drywall/tape. Rehabs : at time of carpet/cabinets Seal windows? Dave will confirm Gaps filled with fiberglass seal? Tried that. Yes, it appears that will work. Any gap 3/8” or narrower. Duct board in aeroseal process of sealing ducts and it works on duct board. Dave will email uc davis guy. Mark Modera at UC Davis developed this technology. Remain sticky/stain over time? A lot of durability testing on duct sealant. Little degradation over time. This sealant has been used for other applications (tremco is manufacturer). Lots of prep work Cover all horizontal surfaces nozzles should be placed, at a minimum, in every bedroom and living area of the apartment nozzles generate a spray jet that travels about 8 feet Cleanable from surfaces
- How is RH maintained? Airflow is monitored and RH of incoming air and heat provided—to determine how much liquid should be injected. At commercialization—this will be automated. Nozzle pressure 60 psi and 90 psi and liquid flow rates between 20 ml/min and 50 ml/min Heating the air in the dwelling will increase the water carrying capacity of the air which allows for higher sealant injection rates and reduced sealing times. Equipment: modified blowerdoor panel, with 2 holes for duct blaster and opening for cables (injection lines, power cords, etc) ductblaster on outside, connected to heater on inside. Protects duct blaster from getting sealant on it. UC davis is looking for manufacturer to commercialize this.
- Pre-sealing: 1 – 2 hrs; Unit Prep (coverings & temp seals): 3 – 7 hours; Seal: 6 – 7 hrs; removal: 1.5 – 3 hrs; post test: 0.5 hr; additional cleanup: 0 to 5 hours. Total: 14 to 22 hours (by researchers who are learning)
- How do you know when to stop? Monitor rate of sealing—looking into this to optimize the cost / benefit. What’s the goal? If energy savings, then stop earlier. If goal is reducing sound transmission, or air transfer, then go longer. Most took 2 hours, ones that went longer had some issues with heater, equipment.
- How do you know when to stop? Monitor rate of sealing—looking into this to optimize the cost / benefit. What’s the goal? If energy savings, then stop earlier. If goal is reducing sound transmission, or air transfer, then go longer. Most took 2 hours, ones that went longer had some issues with heater, equipment.
- The sealant worked very well, sealing the units 54% to 95% tighter than new code requirement of 3.0 ACH50. Blower door fan was measuring between 25 cfm to 114 cfm at 50 pascals after sealing. Approx 1,000ft2 apts Before air-sealing tightness: 2.0-2.9 ACH50 (433 CFM50)
- The sealant worked very well, sealing the units 54% to 95% tighter than new code requirement of 3.0 ACH50. Blower door fan was measuring between 25 cfm to 114 cfm at 50 pascals after sealing. Approx 1,000ft2 apts Before air-sealing tightness: 2.0-2.9 ACH50 (433 CFM50)
- The sealant worked very well, sealing the units 54% to 95% tighter than new code requirement of 3.0 ACH50. Blower door fan was measuring between 25 cfm to 114 cfm at 50 pascals after sealing. Approx 1,000ft2 apts Before air-sealing tightness: 2.0-2.9 ACH50 (433 CFM50)
- Eliminate need for fire caulking penetrations at wall cavities ? Would not eliminate leakage that happens after the sealing (cabinets install, tstat/lighting installs, etc.) 2 parts to the prep: day of—sealing and covering. And days before—work coordination and inspect for readiness. Did 2/day on the first 4-5 hours each NEED FOR BALANCED MECHANICAL VENTILATION! If design previously included bringing in air from outside, than that will need changing: trickle ventilation or balanced ventilation. Not supply only or exhaust only.
- Applications for the program up front