Insulation

Been out-of-town so I missed out on a few days at the building site.  Insulation has begun and our EnergyStar consultant has been visiting the house.  The rigid insulation is being wrapped up outside and the front porch is on as well.  While I was out they didn’t run the insulation all the way down my studio wall when they put the front porch on.  I’m contemplating removing the porch, install the rigid and then lag the north side of the porch through the foam into the studio studs.  On the other areas of the house the ledger board is against the house, my prefered method for structural reasons.  Thermally though this is a train wreck mitigated only by the fact that where the ledger board ends up vertically it’s at or below the floor joists.  We’ll over compensate inside with lots of spray foam in the joist bays atop the Superior Walls.  I can’t do that in my studio.  The issue is compounded because there are water lines that run in that studio wall where the porch meets.  Best thing may be to start over on the front porch.

The fireplace is in, just waiting on the inspection.  I’m getting some feedback on the housewrap on the outside of the chase, but need to check with the inspector, I’m not sure what the issue is.  I also need to bring out the air intake 4″ so it will project past the rigid insulation.  Finally the fireplace installer inserted some pink batt insulation in the chase areas.  We’ll pull that out and make sure it’s insulated properly.

Cost is becoming an issue so we’re cutting back where we still can.  We’ll delay the air cleaner and humidity control on the furnace.  They can be added if necessary down the road.  One nice thing about doing them now was getting the 30% tax credit on the entire geothermal system including these add ons.  But omitting them now saves some money.  We’re also omitting all the stone on the house and will install that after we move in.  Stone is planned to go on the foundation, fireplace, chase, garage and front porch area.  We picked out a really nice cultured stone product that gives a nice stacked stone effect.  No big deal waiting.  Need everything to grow back in before the house is book / magazine photo shoot ready anyway.  Inside we’re reevaluating the kitchen cabinets and may switch to laminate door fronts.  Laminate will be less authentic, but more durable and may be able to get a better match / consistency of color and visual texture vs. playing with real wood.  Countertops may switch from concrete to laminate as well.  Though there are several other materials we’ll look at.

The greenest thing is to buy durable materials that you don’t have to replace down the road. But with every plan, flexibility is the key to success.  There comes a time when various points on the quality, quantity, cost triangle have to move in or out.  We’ll omit the front hall built in for now too, that can wait until we’re moved in.  Items like the screen porch, certain light fixtures and transoms above the bedrooms will wait as well.  Other items can be upgraded down the road such as the lighting in the boys bathroom. Several fundamental items were never up for consideration such as the HVAC hybrid geothermal system, appliances, roof, siding and insulation.  We’re balancing as best we can.

Some items will have to wait til Spring regardless including exterior painting.  It’s just too late in the year to reliable paint the house on the outside.  Siding doesn’t start going on for another week.

Insulating the house takes about 5 working days.  The first few days are spent spraying expanding and non-expanding foam in the joist bays and windows respectively.  ALL wire and pipe penetrations between floors get sprayed with expanding foam.  And all the seams between framing members get caulked to stop air penetration in its tracks.  Seeing this in person is awesom, not the act but rather the result.  I’ve actually dreamt of this day and I’m downright gitty I get to see all the caulk lines in person.  This is so above and beyond what cookie cutter builders have been doing for decades (centuries).  It’s also simple and cost effective.

Here are some pics, enjoy.

Not thrilled with how much 4" rigid we'll lose out on with the ledger board mounted so high on the studio wall. may remove porch and do over. Note, porch ceiling gets OSB and 1" rigid insulation. Should be 2" rigid but lights are designed to slide down only and 1.5" inches. I may box out around lights and add another inch of insulation everywhere else. It's living space above so it's critical this area be air tight and insulated.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Spray foam, roof baffles for air flow and corrugated "blockers" for the end of each rafter bay. Note, when we switched from engineered rafters to stick built, we gained a nice thermal break between the 2x4 and 2x8 rafters as shown here. this kneewall area is our line of defense. We'll insulation and tack up insulation wrap under the 2x4's to keep everything thermally copacetic.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

QuadraFire EDGE60 pellet burning fireplace. Will burn sunflower seeds, corn, sawdust or switchgrass. 4" flue pipe is easy to exhaust, though it's crooked when it exits our house.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Window insulation is non expanding foam. Expanding foam will warp your windows.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

can see white caulk on all framing seams. Expanding foam in joist bays above.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

unfinished fire place chase. not rigid insulation under chase. air intake for fireplace shown.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

styrofoam baffles stapled to underside of roof for proper air flow to keep roof in good shape for years to come.

 
 

Slow But Sure

We’re slowly wrapping up the rough framing and getting ready for insulation.  I met with our EnergyStar rater and insulation contractor this week to do a walk through of the house.  It’s best to know what we need to do before the insulation and drywall start going on.  On the exterior the windows are being installed and the rigid insulation is going up.

There is some concern regarding the HVAC ducts being on exterior walls.  These days most if not all the ductwork should be on interior walls to insulation them from the exterior.  Otherwise it’s difficult to get enough insulation in those wall bays.  At least I’ll have 4″ of rigid insulation on the exterior to mitigate the issue as best we can.  Flexible ducts have been installed in many of the kneewall attic areas of our Cape Cod style home.  This means that in reality we will have to treat all these areas as conditioned space.  This will mean insulating the roof and exterior walls just like the main house, but also using some paper material to prevent air movement.  The paper material will act like drywall in terms of controlling air flow, but will be less expensive to install.  Another concern with the flexible ducts is they were installed with too many tight turns or corners.  Flexible ducts need to have gentle radius turns to keep air and debris from piling up in the corners.

A bit more on insulation.  We’ll be using blown in cellulose insulation made from recycled newspaper.  Fairly green although it is treated to be fireproof.  For air tightness we’ll be caulking the drywall seams so that should minimize any perceived ill effects of the fireproof insulation.  As far as I know it’s a safe product.  Part of the insulation job will include extensive caulking and sealing of the entire house, including around light fixtures, outlets and any wall or floor penetrations.  One place to pay attention to is between the OSB sheets.  Technically the framers should space the sheets 1/8″ apart for expansion.  They usually don’t but regardless, any visible gaps in the OSB should be sealed with spray foam from the inside.  On our house there are a couple of areas where you can see daylight shining through the green Raindrop housewrap, between the OSB wall sheathing.

We’ll be having a blower test and filling out three sets of survey forms to establish our home’s HERS rating and ultimately our EnergyStar qualification.  It’s critical that the house essentially be air tight.  I Googled it and it looks like Ohio has about 1,300 EnergyStar homes so we’ll be in the vast minority.  Hopefully in a few years this will be the norm.

On the exterior we continue to pick away at sealing everything and installing the blue rigid insulation.  Windows are starting to go in.  We seat the aluminum nailing flanges of each window in a bead of silicone sealant / caulk and level / nail the windows in place.  Over the top of the flanges, just like our REMOTE wall article says to do, we cover with Grace Vycor Plus membrane flashing.  The insulation contractor will seal everything up from the inside with spray foam and caulk where necessary.

The windows show up with a breather tube and mylar expansion bag.  Serious windows do this because all the windows are gas-filled. Without the tubes the windows would explode when they’re driven over the Rocky Mountains.  Without the mylar balloon the gas would escape.  One of the balloons did get cut so I suspect we’ll have to have a tech come out and refill that window.  On all the other windows, I’ve been crimping the tube in two places and will cut off the mylar balloon.  I then hit the end of the tube with silicone caulk and then tuck it into the window frame.  The gas should stay in the windows for 100 years.  Definitely not my problem then.

On the exterior we’re installing aluminum termite shield to protect the bottom of the rigid from ant / bug infestation.  We simply bought some white aluminum sheet metal and bent it up to form an “L” with a little lip for water run off.  The termite shield gets tacked up behind the housewrap at the bottom of the exterior walls.  It overlaps the foundation by about 2-3 inches.  Resting on top of the termite shield and housewrap are our 2×8 foot  x 4 inch thick sheets of Dow blue rigid insulation.  The rigid is installed by tacking the panel with a couple of screws.  We then come back through and put 1×3 firring strips over the vertical seams.  The horizontal seams get a one foot strip of Raindrop; it’s zig zagged with 4″ stapled above the panel against the existing housewrap, then 4″ runs across the top of the insulation panel, and finally the last 4″ flaps down over the top of the panel.  If our panels weren’t so dirty we’d just tape all the seams.  The firring strips will help give us a decent seal as will the housewrap strips.  We use 8″ screws to secure the firring strips to the wall (passing through the rigid insulation).  Try to hit studs with every screw.  Otherwise the screw will act as a conduit for cold or heat.  We missed a ton and technically should back out the screws and try again, but it’s painfully slow already so we’ll snip the exposes screws and I’ll kit them with some foam insulation.  Should be alright, even for Ohio.

One interesting thing I came up with this week, the loft window is showing up late but we need to get the blue board in place ahead of time.  Once the blueboard is in I won’t be able to get the membrane flashing in place.  So I took strips of it and left the backer paper on and stuck the rest to the window buck perimeter.  After the window is in they can remove the paper and stick it over the flanges.

Here are some new pics from the last few days.

 

 

 

 

 

 

 

 

 

 

 

 

 

blue foam with housewrap horizontal "z" at joint

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

detail of housewrap "z" at horizontal joints of rigid insulation.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

column pads for porches are finally poured. sono tubes shifted so much, threaded bolts are barely in pad. Bad workers, bad.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

to remove just the backer paper from half a strip of Vycor membrane flashing, I use a common nail.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

I remove half the backer paper so I can stick the strip around window buck. Once back ordered window is in I can stick the rest. In the meantime I don't hold up blue foam installation.

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

termite shield

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

window breather tube and balloon