USDAUSDA ForestForest Service,Service ForestForest ProductsProducts LaboratoryLaboratory ResearchResearch DemonstrationDemonstration HouseHouse andand CarriageCarriage HouseHouse A Walkthrough Tour USDA Forest Service Forest Products Laboratory One Gifford Pinchot Drive Madison, Wisconsin 53726-2398 Phone: (608) 231-9200 Internet: www.fpl.fs.fed.us

June 2010

The USDA prohibits discrimination in all its pro- grams and activities on the basis of race, color, na- tional origin, age, disability, and where applicable, sex, marital status, familial status, parental status, religion, sexual orientation, genetic information, political beliefs, reprisal, or because all or a part of an individual’s income is derived from any public assistance program. (Not all prohibited bases ap- ply to all programs.) Persons with disabilities who require alternative means for communication of program information (Braille, large print, audio- tape, etc.) should contact USDA’s TARGET Center at (202) 720–2600 (voice and TDD). To file a com- plaint of discrimination, write to USDA, Director, Office of Civil Rights, 1400 Independence Avenue, S.W., Washington, D.C. 20250–9410, or call (800) 795–3272 (voice) or (202) 720–6382 (TDD). USDA is an equal opportunity provider and employer. Welcome

Research on wood-frame housing has been an im- Demonstration House and the Carriage House. For Thomas G. Williamson portant part of the 100-year research program at convenience, each item includes one or more pho- Vice President of Quality and Technical (Retired) the USDA Forest Service, Forest Products Labora- tographs and follows a designated path covering APA – The Engineered Wood Association tory (FPL). To further these efforts, FPL established the outside and inside of both structures. Please the Advanced Housing Research Center (AHRC) in keep in mind that these structures were designed Catherine Marx Kaake 2000. Originally organized to further cooperation and built to represent a “typical” structure for Senior Director, Engineered & Framing Markets between federal agencies as part of the Presiden- research purposes, not a “perfect” structure. Also Southern Pine Council tial Initiative, Partnership for Advancing Technol- remember that the FPL housing research program Michael A. Ritter ogy in Housing, the AHRC has grown to include a is dynamic, and changes may occur periodically Assistant Director wide range of partners from both the public and that affect the nature of the research and the ap- USDA Forest Service, Forest Products Laboratory private sectors. pearance of the structures. Martin R. Yoklic Under the auspices of the AHRC, FPL has con- On behalf of all the partners and many FPL em- Research Scientist structed two full-scale structures for research and ployees who developed and continue to work on Environmental Research Laboratory, educational activities: the Research Demonstra- the Research Demonstration House and the Car- University of Arizona tion House and the Carriage House. Both of these riage House, we hope your visit will be informative structures allow researchers to conduct housing- and interesting, and we invite your questions and Susan LeVan-Green related studies in a “real world” setting, which can comments. For additional information on both re- Program Manager, Technology Marketing Unit significantly extend knowledge obtained in a labo- search and educational topics, please visit the FPL U.S. Forest Service, Forest Products Laboratory ratory environment. The Research Demonstration website at www.fpl.fs.fed.us. House and the Carriage House have also helped The first to further FPL collaboration and partnerships with FPL test house industry, academia, and other government entities. was built in the 1930s to evalu- This is not the first time housing structures have ate moisture distribution been built at FPL. The first full-scale structure was and tempera- built in the late 1930s to evaluate moisture distri- ture gradient in bution and temperature gradients in wood- walls. framed walls. It is also interesting to note that the Research Demonstration House and Carriage House are located on the same site as the origi- nal farm house and outbuildings for the farmland where the current FPL campus was built in 1930 (see next page). This publication is intended to provide a brief overview of the products, technologies, and re- search activities that are included in the Research

Research Demonstration House—Welcome 1 Then and Now

1930

2010

2 Research Demonstration House

Then and Now Site Map ͢ North

Parking Lot

Research Demonstration House Carriage House

Research Demonstration House and Carriage House—Site Map 3 Research Demonstration House

The Research Demonstration House is a 2,300-square-foot, two-story structure that is based on a standard architectural design and was built to represent a “typical” Midwestern house. Constructed in 2001, the house was originally conceived to conduct full-scale research studies on moisture management practices in a cold climate region. At the time of construction and continuing now, moisture and mold are significant national issues, and research was needed to educate builders and consumers on the best recommended prac- tices to minimize adverse moisture effects on the structure and indoor living environment. Under the leadership of APA – The Engineered Wood Association (APA), a partnership to construct the house was formed involving APA, the Southern Pine Council, Windsor Homes, the USDA Forest Service, Forest Products Laboratory, and numerous product manufac- turers and suppliers. During the late project planning stages, the partners determined that the house interior would be finished and that materials and technologies would be included to demonstrate energy efficiency, sustainabil- ity, and water efficiency. Although research is the primary purpose for the house, it is also intended to be an educational experience for all who visit.

4 Research Demonstration House Research Demonstration House Outside

Lap Brick Panel Stucco

Ramp Siding The ramp from the sidewalk and parking area to The type of exterior siding can influence moisture the wood framing with connector straps, there is the front porch not only provides accessibility to behavior inside the wall. Because moisture research a ventilation gap and a moisture barrier between the house but also is an ongoing research project is a key objective for this house, four different the brick and the wood framing to reduce the to evaluate long-term durability of decking and materials cover the exterior: brick veneer, stucco, potential for moisture accumulation. ramp support materials. Constructed of naturally plywood panel siding, and lap siding. The various • The wood panel siding is specially manufactured decay-resistant wood species, preservative-treated materials were installed using consistent flashing plywood and is commonly referred to as APA wood, and wood–plastic composite lumber, the and sealant techniques and now are being moni- T1-11. The siding panels are available in various structure is being monitored to determine how tored to determine how much moisture penetrates designs and textures and are typically 4 feet wide well the materials stand up to the elements. The the surfaces. Brief descriptions of the different sid- and 8 to 10 feet long. different materials that are being evaluated are ing materials follow. Plywood siding provided by McKenzie Forest labeled along the length of the ramp: • The nominal 8-inch-wide oriented strandboard Products, Springfield, OR. • Nine different formulations of wood- lap siding is an engineered wood product that is • The stucco siding is made using a cement mixture preservative treatments shipped pre-primed and treated with borate to combined with water and sand or lime. It is typi- inhibit decay and insect attack. It is nailed to the • Four types of wood–plastic composite lumber cally installed over a wire mesh (similar to chicken wood frame, edge sealed, and painted (a siding using both polyethylene and polypropylene wire) that is placed over building paper on the sample is on display in the basement). plastics wood frame. SmartSide® lap siding provided by LP Corpora- • Untreated black locust and ipe (naturally decay- tion, Huntersville, NC. resistant wood species) • Brick veneer siding is constructed by building a The ramp railing is finished with a penetrating oil wall of clay bricks with cement-based mortar in stain that was developed at FPL. front of the wood framing. Although attached to

Research Demonstration House—Outside 5 Outside

Collection Barrels

Roof Shingles Rainwater Harvesting The roof shingles appear to be hand-split cedar Rainwater collection has been practiced for thou- Drain Field shakes but are actually a wood–plastic compos- sands of years, although it is generally not wide- ite material made from waste wood and recycled spread where safe and abundant water is supplied This type of system can provide irrigation for a plastic milk containers. They are molded in by public and private utilities. However, dimin- long hedge or other landscaping features. The lightweight panels that can be cut and nailed in ishing water supplies due to drought, increased second system involves two rainwater collec- place, without the use of special tools. Construc- demand, pollution, and inefficient use are elevating tion barrels that store water collected from the tion scrap is easily recycled to manufacture more water conservation as a topic of great interest. In roof, which can then be tapped with a hose to shingles. The finished roof is both fire and hail re- residential applications, harvested rainwater can be provide landscape irrigation. sistant and carries a Class A fire rating and a Class used for many purposes, including toilets, laundry, Rainwater harvesting research conducted in C hail rating. Researchers are studying long-term and lawn and garden irrigation. At this house, re- cooperation with the University of Arizona. shingle durability and expect the product to last searchers are evaluating a number of water har- for many years. At this time, the shingles are in a vesting systems that can significantly reduce the development phase and are not available for sale residential water demand on the public water util- to the public. A shingle panel is available for view- ity. Evaluating the performance of these harvesting ing in a second floor bedroom of the house. systems for cold climate applications will aid in the development, design, and construction techniques Roof shingles supplied by Teel Global Resource employed for future systems. Technologies, Baraboo, WI. Two different rainwater harvesting systems can be seen outside the house. The first is a simple drain field where water from the roof is directed un- derground via a long perforated plastic pipe to a gravel leach field under the grass in the side yard.

6 Research Demonstration House—Outside Outside Outside

Lift Station Drain Field Front Porch The round concrete cylinder at the southeast The front porch flooring is nominal 1- by 4-inch corner of the house covers a sewage lift station. tongue-and-groove Southern Pine that is nailed in Rear Porch and Stairs Because of the relatively low elevation of the base- place and finished with an oil-based wood stain. ment, and the fact that the house is not located in The back deck, framing, and stairs are made from The ceiling is the same material, but the boards a conventional housing area, the lift station was pressure-treated Southern Pine lumber. This mate- are reversed to show a beaded pattern on the rial has been widely used as a decking material for required to raise sewage to the city sewer pipe side opposite the smooth finish side (material over 60 years, and industry analysts report that elevation. samples are on display in the basement). Note that more than 70% of all decks in the United States a problem has developed and water vapor from are pressure-treated Southern Pine. The treated the house interior is venting above the ceiling and material is strong, durable, and can be stained to condensing on the cold ceiling surface. This is any color. The reasonable life expectancy of the ex- causing the ceiling boards to swell and buckle. posed boards with regular maintenance is approxi- Flooring and ceiling planks provided by the South- mately 20 years, depending on climatic conditions. Sealing the boards regularly with water protective ern Pine Council, Kenner, LA. coatings or stains can extend the life expectancy to up to 30 years. Decking and framing material provided by the Southern Pine Council, Kenner, LA.

Research Demonstration House—Outside 7 First Floor

Rear Porch

Breakfast Kitchen

R Great DN Room

W D

UP

Dining Garage

Porch

8 Research Demonstration House—First Floor First Floor First Floor

Wisconsin ENERGY STAR® Certification Douglas-fir Desk This house is certified by Wisconsin ENERGY House Design and Plans This desk was built using wood from small-diam- STAR® Homes, which means it is The “Hazelton” house design was selected by our eter, suppressed-growth trees that were removed • built to proven standards that ensure superior industry partners because it is popular and a “typi- from the forest during thinning operations. Public insulation, ventilation, combustion safety, and cal” design that uses a wide range of sustainable and private forests are in critical need of resto- moisture control, engineered wood products. The two-story design ration. Thinning small-diameter trees improves • estimated to be 25% more efficient than homes includes approximately 1,132 square feet of living forest health and reduces the risk of catastrophic built to the Wisconsin Uniform Dwelling Code, space on the main floor, 1,087 square feet of living wildfire. Most of the trees obtained from thinning and space on the second floor, a full basement, and a are between 3 and 9 inches in diameter and are two-car garage. Because most of the materials and too small for commercial manufacturing. However, • performance tested and certified by third-party a portion of the labor were donated, the actual products such as this desk demonstrate the use of consultants. cost of the house is impossible to determine; a low-value material to create a high-value prod- The Wisconsin ENERGY STAR® Homes program however, a 2001 cost estimated by the builder was uct. These products can provide economic benefits helps to preserve Wisconsin’s environment be- approximately $250,000. to local communities, help offset thinning costs, cause less energy use means fewer environmental and improve forest health. House design and plans supplied by Design Basics, effects on our air, water, and land. To date, more Omaha, NE. Desk supplied by Jefferson State Forest Products, than 350 builders have partnered with Wisconsin Hayfork, CA. ENERGY STAR® Homes to build more than 8,000 new high-performance homes across the state.

Research Demonstration House—First Floor 9 First Floor

Lighting Low-VOC Paint Southern Pine Flooring Lighting accounts for about 20% of the electric Most paints contain chemicals known as volatile Flooring in the great room and dining room (serv- bill for an average home. Wherever possible, the organic compounds, or VOCs. These are carbon- ing as our reception area) is plantation-grown lighting fixtures in this house meet or exceed containing compounds that readily vaporize Southern Pine. The flooring consists of nominal ENERGY STAR® requirements. ENERGY STAR® into the air as paint dries. VOCs react with other 1- by 4-inch tongue-and-groove boards that are qualified lighting provides bright, warm light but elements to produce ground-level ozone, which nailed in place. After installation, the flooring was uses approximately 75% less energy than standard can cause air pollution and can potentially cause sanded and finished with several coats of clear lighting, produces 75% less heat, and lasts up to health-related concerns, especially breathing- polyurethane finish. 10 times longer. By replacing the five most fre- related disorders such as asthma. To reduce the Flooring provided by the Southern Pine Council, quently used light fixtures in a home with ENERGY release of these compounds into the air, low-VOC Kenner, LA. STAR® qualified models, you can save more than paints have been developed. To qualify as a VOC- $65 each year in energy costs. compliant paint, the U.S. Environmental Protec- tion Agency requires a VOC level of less than 250 Lighting provided by Progress Lighting, grams per liter for latex and flat finish paints and Spartanburg, SC, and Wisconsin ENERGY less than 380 grams per liter for oil-based and all STAR®. other paints. The paint used for the interior of this house is a very low VOC latex formulation, con- taining less than 50 grams per liter. Paint provided by Sherwin-Williams, Strongsville, OH.

10 Research Demonstration House—First Floor First Floor First Floor

Digital Programmable Thermostat Automatic Humidifier Control Smoke Alarms and Zone Control This wall-mounted control unit is connected to One of the most important safety devices for the home is a smoke alarm. In the event of a fire, Digital programmable thermostats allow the ho- a centralized, computer-controlled humidifier properly installed and maintained smoke alarms meowner to turn on the heating or air condition- attached to the forced-air heating system in the will provide an early warning to facilitate a safe ing according to a pre-set schedule. As a result, basement. The humidifier continuously measures, evacuation. Smoke alarms are of two basic types: the temperature can be automatically adjusted controls, and delivers optimum levels of moisture ionization alarms and photoelectric alarms. Ioniza- during sleeping periods or when the house is not to indoor air based on the dial setting selected tion alarms sound more quickly when a flaming, occupied. Programmable thermostats can store by the homeowner. A centralized unit such as this fast-moving fire occurs. Photoelectric alarms are and repeat a number of daily settings that can be delivers humidified air to the entire house through quicker at sensing smoldering, smoky fires. Combi- manually overridden without affecting the auto- the forced-air system, providing greater uniformi- nation smoke alarms combine ionization and pho- matic daily or weekly program schedule. Turning ty, accuracy, and reliability compared to individual toelectric capabilities into one unit. Because both back the thermostat 10% to 15% for 8 hours daily room humidifiers. ionization and photoelectric smoke alarms are can save as much as 10% on annual heating and Aprilaire® computer-equipped automatic humidi- better at detecting distinctly different yet poten- cooling costs. fier and control unit provided by Research Products tially fatal fires, the installation of both ionization In addition to the thermostat on the first floor, Corporation, Madison, WI. and photoelectric or dual sensor smoke alarms is a similar unit is located upstairs in the master recommended. Residential smoke alarms should bedroom to control air temperature on the second be placed on all floors in accordance with manu- floor. This effectively divides the house into two facturer recommendations and may be battery heating and cooling zones and allows the home- operated or wired directly into the house electri- owner to set each zone temperature depending on cal system. Direct-wired alarms should also have a room occupancy and time of day. Combined with battery backup. Batteries must be checked often programmable thermostats, zoning can reduce and replaced annually. energy costs by up to 20%. Aprilaire® digital thermostat and zone control system provided by Research Products Corporation, Madison, WI. Research Demonstration House—First Floor 11 First Floor

Moisture Windows Research The ENERGY STAR® qualified windows in this Moisture movement house allow the occupants to enjoy the light and and accumulation outside view while saving money on utility bills is a main research and protecting valuable furnishings and finishes focus of the Research from sun damage. Products labeled with the Demonstration House. ENERGY STAR® logo must meet strict energy- The purpose of this efficiency guidelines set by the U.S. Environmen- research is to better tal Protection Agency and the U.S. Department understand moisture of Energy. They save energy and money for the in order to minimize homeowner and help the environment because the potential for lowering energy use helps reduce greenhouse gas moisture damage to emissions and air pollutants at the source. wood-frame housing ENERGY STAR® windows feature advanced tech- and improve energy nologies such as invisible glass coatings, vacuum- efficiency and indoor sealed spaces filled with inert gas between the two air quality. As part of this effort, researchers are panes, improved framing materials, better weather looking at how moisture content in exterior walls stripping, and warm edge spacers, all of which varies with season, weather, and type of wall con- reduce undesirable heat gain and loss. Compared struction. A key factor that influences moisture in ex- to less efficient windows, ENERGY STAR® qualified terior walls, especially in cold climates during winter windows help keep homes warmer in the winter months, is the level of indoor humidity. Because this and cooler in the summer because they can block house is unoccupied, humidifiers are used to simu- 70% or more of the solar heat gain in the summer late the humidity level that results in an occupied and reflect radiant heat indoors during winter. As home from activities such as showering, cooking, is the case with the windows in this house, an and cleaning. Moisture management guidelines ENERGY STAR® qualified window with special generally recommend that indoor relative humidity (Low-E) coatings can reduce fading and discolor- not exceed 40% during winter in cold climates. For ation from direct sunlight exposure by up to 75%. research purposes, this house is humidified during the winter to approximately 45% relative humidity Windows provided by Andersen Windows, Bayport, at 70°F. This level is much higher than average and MN. would be exceeded by only one out of 10 houses in the Madison, Wisconsin, area. Moisture research instrumentation, including pressure-measurement tubes and sensor wires, is plainly visible along the living room walls.

12 Research Demonstration House—First Floor First Floor First Floor

Ceiling Fans Ceiling fans are installed in the living room and several other rooms in the house. The fans do not actually change the temperature in a room, but they circulate the air for a beneficial effect in both Fireplace Maple Flooring summer and winter. In the summer, ceiling fans The fireplace is a direct-vent, high-efficiency gas The kitchen flooring is nominal 1- by 4-inch create a wind chill effect that pulls perspiration unit equipped with a fan to distribute heat into tongue-and-groove maple that is nailed to the away from your body, allowing your body’s own the room. Direct-vent units eliminate the need for subfloor. This flooring is different from other wood cooling system to work more effectively. When a chimney and chase, allowing for less expensive flooring in the house because it is factory sanded used with central air conditioning, ceiling fans can installation and positioning virtually anywhere and finished for quick and easy installation. compensate for an increased thermostat setting in the house. The air-tight construction provides of as much as 10 degrees without a noticeable de- Maple flooring provided by Somerset Wood Products, an authentic flame while maintaining indoor air crease in the comfort level. Ceiling fans cost about Somerset, KY. quality, because the combustion air comes from 3 cents per hour to operate, and an air condition- outside the house and exhaust is expelled through er can cost more than $1.00 per hour to operate an outside vent. Fireplaces such as this add to the (depending on efficiency)—considerable savings comfort of your home by providing warmth and in air conditioning costs can be realized by using ambience at the touch of a button. a ceiling fan. During winter, ceiling fans pull cooler air from the floor upwards toward the ceiling Vermont Castings fireplace provided by United Brick where it mixes with warmer air and circulates and Tile, Madison, WI. with the least direct air movement and wind chill effect. Ceiling fan/light combination units that are ENERGY STAR® certified are about 50% more efficient than conventional fan/light units and can save more than $15 per year on utility bills. Ceiling fans provided by Craftmade Company, Coppell, TX, through Isthmus Lighting, Madison, WI.

Research Demonstration House—First Floor 13 First Floor

Kitchen Countertops The kitchen countertops are made of medium-density fiberboard (MDF) covered with a decora- tive plastic laminate. MDF is an engineered wood product that is formed by breaking down soft- wood into fibers that are com- bined with wax and a resin binder and are formed into panels by applying high temperature and pressure. MDF does not respond significantly to changes in mois- ture or temperature and provides a dimensionally stable platform for the plastic laminate. This type of countertop is very common and is Kitchen Appliances factory produced with a single thin The kitchen appliances were all state-of-the-art when Kitchen Cabinets sheet of plastic laminate curved the house was built in 2001. However, at that time and glued over the MDF base the dishwasher was the only appliance available with The kitchen cabinets are made from maple, which material, which is shaped to provide an integrated an ENERGY STAR® certification. ENERGY STAR® is a strong, heavy hardwood that is commonly front edge, work surface, and backsplash. This type dishwashers, such as the one in the kitchen, use at used for cabinets and furniture. They are “stock” of countertop is economical, durable, and does not least 41% less energy than the federal minimum cabinets that were manufactured in an industrial require maintenance, such as resealing or heavy standard for energy consumption and use much less facility and are available in standard designs, polishing. water than conventional models. Since the house was rather than “custom” cabinets that are specifically Countertops provided by VT Industries, Holstein, IA. built, ENERGY STAR® certification has also been de- designed and built for a single, specific loca- veloped for refrigerators. Today, ENERGY STAR® re- tion. Stock cabinets are typically less expensive frigerators use at least 20% less energy than required than custom cabinets and are readily available by federal standards and about 40% less energy than in a wide variety of standard designs for timely the conventional models sold in 2001. installation. These cabinets were certified by the Kitchen Cabinet Manufacturers Association Cer- There is no ENERGY STAR® label for the other tification Program, which evaluates cabinets for kitchen appliances in this house, but the comparative structural, construction, and finish requirements energy efficiency between models can be determined that simulate years of household use. by the EnergyGuide labels that are placed on all new appliances. This label gives the estimated energy Cabinets provided by Quality Cabinets, use per year and the annual energy use range of all Duncanville, TX. similar models of that appliance type. Kitchen appliances provided by Whirlpool Corporation, 14 Research Demonstration House—First Floor Benton Harbor, MI . First Floor First Floor

of different models can be determined by compar- ing EnergyGuide labels that are placed on all new appliances. The label gives the estimated energy use per year and the annual energy use range of all similar models. Washing machine and dryer provided by Whirlpool Corporation, Benton Harbor, MI.

Washer Safety Valve The safety valve behind the washing machine automatically shuts off the hot and cold wa- Washing Machine and Dryer ter supply when the As with the kitchen appliances, the washing ma- machine is not in use. chine and dryer were state-of-the-art when the When the washer is on, house was built in 2001. The washing machine is the device senses the ENERGY STAR® compliant and operates without electric current flow to an agitator. Instead, the wash plate at the bottom the washer and opens of the basket lifts, rolls, and bounces the clothes, the water valves. When which reduces the amount of hot water required the washer shuts off, the and the energy used to heat it. ENERGY STAR® device senses the stop in current flow and closes qualified washing machines typically use 50% less the water valves. This simple device can prevent energy than standard washers and only 18 to 25 thousands of dollars in damage due to a broken gallons of water per load, compared with 40 gal- or split washer hose—and the resulting flooding— lons used by a typical standard machine. They also while the machine is unattended. extract more water from clothes during the spin Washer Safety Valve provided by CasMont Indus- cycle to reduce drying time and save energy. tries, Inc., Louisville, KY. There is no ENERGY STAR® label for clothes dry- ers because there is little difference in the energy use between models. The relative energy efficiency

Research Demonstration House—First Floor 15 Garage

Rainwater Holding and Distribution System The 300-gallon storage tank located in the garage is part of a rainwater collection system that sup- plies water to the washing machine and first-floor bathroom toilet. The system could also be modi- fied to supply rainwater for other non-potable water uses in the house. Rainwater is collected from the southwestern roof of the Research Dem- onstration House and is channeled by gutters and an overhead inflow pipe to a 25-gallon filter box above the tank. During periods of rainfall, the filter box fills first to remove debris that may enter the system during the initial flow. After the filter box fills, water flows into the storage tank. Moisture Research Data Collection The remainder of the distribution system includes Hundreds of sensors are positioned throughout a pump, pressure tank, relay circuits, water level the house to obtain temperature, relative humid- sensors, and solenoid valves. When the water level ity, air pressure, and moisture levels in the walls. in the tank is low, the system automatically shifts Readings from instrumentation are automatically to the municipal water supply. When the rainwater obtained and recorded by a computerized data inflow exceeds tank capacity, the overflow is -di acquisition system. Long-range seasonal trends, rected to an overflow pipe and is drained into the weather changes, and daily patterns are collected subsurface irrigation field on the north side of the by data loggers in the garage and basement and house. Backflow preventers control the direction of are archived to a computer. Pressure measure- rainwater flow to prevent rainwater from moving ments in wall cavities and wind speed and direc- into the municipal supply. tion are collected every 30 seconds. Moisture and Rainwater harvesting research is in cooperation temperature change much more slowly and are with the University of Arizona. recorded every hour. A full weather station and display of outside weather conditions on a base- ment computer are also part of the data collection system.

16 Research Demonstration House—Garage Garage Second Floor

Master Bedroom

DN Bedroom 4

Bedroom 2 Bedroom 3

Research Demonstration House—Second Floor 17 Second Floor

Interior Doors The interior doors are made from loblolly pine that is sustainably managed and grown in planta- tions. The wood is known for both strength and beauty. Loblolly pine lumber has been produced in the mountain region of Arkansas since the early 1900s. Drying is a critical process in produc- ing this quality lumber. Specifically designed kilns allow lumber to be dried on a computer-con- trolled extended cycle, with a steam conditioning cycle to ensure stability and good surface char- acteristics. After drying, the lumber is specially packaged in protective material and shipped to Carpet and Padding the manufacturing facility where it is milled and manufactured into doors. Carpeting in the upstairs hallway is made from 100% continuous filament polyethylene tere- Lumber provided by Weyerhaeuser, Hot Springs, phthalate (PET) polyester. It is manufactured from AR. recycled plastic beverage containers, which are re- quired by the U.S. Food and Drug Administration to use only the highest quality PET resins. Carpet manufactured from this recycled material is inher- ently stain and moisture resistant. The padding under the carpet is manufactured from recycled foam that is chopped, shredded, and bonded into one solid piece, approximately 1/2 inch thick. In both cases, the materials are typically considered waste and would otherwise be discarded in landfills. Carpet provided by Shaw Floor Alliance and pad- ding provided by Future Foam, Middleton, WI, through ProSource Wholesale Floor Coverings, Madison, WI. Carpet installation provided by Coyle Carpet One, Madison, WI.

18 Research Demonstration House—Second Floor Second Floor Second Floor

Moisture Research Instrumentation Air movement is an impor- tant factor that affects the moisture levels in wood frame walls. FPL researchers have collaborated with researchers at Syracuse University to gain insight to how airflow contrib- utes to wetting and drying. The research at Syracuse in- volves laboratory experiments and computer modeling to Douglas-fir Flooring complement the ongoing Window Treatments studies in the Research Demonstration House at The floor in the master bedroom (bedroom 1) is FPL. In this study, researchers removed the cel- Window treatments, such as blinds and shades, nominal 1- by 3-inch tongue-and-groove Douglas- lulose insulation from one wall cavity and then are commonly used to provide privacy and to fir that was nailed to the subfloor and sanded measured airflow through the various connections protect interior furnishings such as furniture and after placement. It was finished with a linseed oil around the perimeter of the cavity (for example, carpet from the damaging effects of solar ultravio- sealer followed by several coats of a water-based between a 2 by 6 stud and the exterior sheathing). let radiation. To some degree, most window treat- catalyzed urethane acrylic finish. The flooring was Air moves in response to pressures that can be ments also block solar heating in the summer and manufactured from suppressed-growth, small-di- induced by wind, temperature differences, or fans reduce heat loss in the winter. The cellular shades ameter Douglas-fir trees that were obtained from inside the house. Researchers then placed dozens in bedroom 1 are made with air cells or pockets forest thinning. As is the case for the Douglas-fir of sensors in the wall cavity and installed fiberglass that provide a buffer between the house interior desk on the first floor, using low-value material batt insulation to replace the removed cellulose and the outdoors. This air buffer creates an insu- from forest thinning to create products such as this insulation. The sensors in the wall monitor temper- lating effect that reduces energy consumption by flooring provides economic benefits to local com- ature, relative humidity, air pressure, and moisture reducing solar heat gain in the summer and heat munities, helps offset thinning costs, and improves content. Additionally, an anemometer on the roof loss in the winter. Additionally, the cellular design forest health. measures the wind speed and direction. Research- helps to absorb sound and control unwanted Flooring provided by Jefferson State Forest Products, ers have found that the dominant airflow pathway outside noise. is between the wall cavity and the attic. Ongoing Hayfork, CA. Window treatments provided by Graber through analysis of the data will show how the airflows Springs Window Fashions, Middleton, WI. relate to moisture levels. Moisture research is in cooperation with Syracuse University.

Research Demonstration House—Second Floor 19 Second Floor

Carbon Monoxide Detectors Carbon monoxide (CO) is a gas that cannot be seen, tasted, or smelled, but it can be lethal at high concentrations. The most frequent causes of excessive CO in a resi- dential environment are faulty or misused fuel- burning devices that Skylight are commonly used for heating or cooking (such as portable fuel-burning Skylights provide up to 30% more luminescence heaters, blocked chimneys or flues, and gas grills), than vertical windows, allowing homeowners to electric generators, and vehicle engines. A CO de- maximize the benefits of natural lighting and save tector is a device that senses high concentrations on electric lighting costs. The Low-E insulating of CO and sounds an alarm to warn of impend- tempered glass used here promotes energy ef- ing danger so the area can be evacuated and Wood–Plastic Composite Shims ficiency and is approximately 35% more efficient ventilated. CO alarms may be battery powered, Shims are commonly used in the installation of than ordinary dual-pane glass in the heating installed in a plug-in receptacle, or wired directly windows, doors, and cabinets. The shims around months and approximately 41% more efficient in into the electrical system. Units that are recepta- this closet door are manufactured by molding the cooling months. cle-mounted or are wired directly into the electri- polypropylene plastic and waste wood fiber into a Skylight supplied by Andersen Windows, Bayport, cal system should also have a battery backup. CO consistent shape and size. The shims can be nailed MN. detectors should always be installed in accordance and cut with conventional woodworking tools and with manufacturer’s instructions. It is generally offer advantages over conventional wood shims recommended that detectors be installed in the because they resist splitting, splintering, warping, hallway outside bedrooms in each separate sleep- and twisting. They are also resistant to fungal at- ing area. Locations to be avoided include kitchens, tack and swelling due to moisture exposure. near heating vents or fuel burning appliances, and where the detector can be covered by furniture or Shims manufactured by Teton West Lumber Com- draperies. pany, Cheyenne, WY, using materials provided by Teel-Global Resource Technologies, LLC, Baraboo, WI.

20 Research Demonstration House—Second Floor Second Floor Second Floor

Deconstructed Wood Flooring Wood Trusses Air Chutes The flooring in bedroom 2 is made of old-growth The house roof system is supported by wood The blue polystyrene panels placed between the Douglas-fir salvaged from deconstructed military trusses constructed of nominal 2-inch-thick South- lower sections of the trusses are air chutes. These barracks originally built in the 1940s. Through ern Pine lumber. The trusses are structural frames chutes allow air movement between the attic and a research program at FPL, deconstruction and consisting of a triangular arrangement of lumber the soffit vents under the roof overhang. Without reuse of materials from existing buildings is being members that transfer loads to the supports. The the chutes, attic insulation could block soffit vent developed as an alternative to conventional de- lumber is joined with toothed connector plates openings and prevent outside air flow from cir- molition and landfill disposal. An estimated billion stamped from galvanized steel sheet metal of culating in the attic, which could lead to moisture board feet of lumber is landfilled in the United different grades and thicknesses to provide the accumulation and eventual damage. Air chutes States each year. Deconstruction offers a means required load transfer. Virtually any roof shape or also protect attic insulation from wind washing or of reusing this material for valuable products and area can be achieved using the unique flexibility of uncontrolled movement of outside air through the can provide opportunities for local employment. wood trusses. Approximately 90% of the residen- insulation, which can compromise the ability of the tial roofs constructed in the United States use insulation to resist heat flow. Flooring material provided by Ft. Ord Reuse Au- wood trusses of this type. thority, Marina, CA. Truss lumber provided by Georgia-Pacific Corpora- tion, Atlanta, GA. Plates and design provided by Alpine Engineered Products, Pompano Beach, FL. Fabrication by Windsor Homes, Madison, WI.

Research Demonstration House—Second Floor 21 Second Floor

easier to save water and protect the environment. Following are a few examples of fixtures that have the highest water saving potential: • Toilets—Older, inefficient toilets use between 3 and 7 gallons of water per flush and are the source of most wasted water in American homes. The average person will flush the toilet more than 100,000 times over a lifetime. Replac- ing older toilets with WaterSense® labeled high-efficiency toilets could save nearly 2 billion gallons per day across the country. • Faucets—Faucets account for more than 15% of indoor household water use—more than 1 tril- Finger-Jointed Studs lion gallons of water in the United States each year. Faucets typically flow at approximately 2.2 All studs in this house are finger-jointed South- gallons per minute. WaterSense® labeled bath- ern Pine lumber, designed and manufactured for room sink faucets can reduce water flow by 30% vertical-use structural applications. Finger-joints or more without sacrificing performance. are interlocking grooves cut into the ends of • Shower heads—Showering represents approxi- lumber pieces that may be joined together with mately 17% of residential indoor water use in adhesives to form long pieces (see wall cutout). the United States, more than 1.2 trillion gallons Finger-jointed lumber creates a use for short- each year. The average 8-minute shower with a length lumber pieces that may be by-products of 2.5-gallon-per-minute showerhead will use 20 other manufacturing processes and would oth- gallons of water. By simply installing a 1.75-gal- erwise be considered waste. When compared to lon-per-minute showerhead, water consumption conventional sawn lumber studs, finger-jointed Plumbing Fixtures for an 8-minute shower can be reduced to 14 studs are more dimensionally stable and are less Many American families use hundreds of gal- gallons. likely to warp or twist because they are manufac- lons of water each day. However, there are many tured from dry lumber. Exterior walls use nominal opportunities to conserve our water resource Plumbing fixtures provided by Kohler Company, 2- by 6-inch studs placed at 24 inches on-center. through reduced use and the use of water-effi- Kohler, WI. Interior walls are nominal 2- by 4-inch studs at 16 cient fixtures. All plumbing fixtures in this house inches on-center. were state-of-the-art for water conservation when Finger-jointed studs provided by Georgia-Pacific the house was built in 2001. Since that time, there Corporation, Atlanta, GA, and New South Compa- have been further technological advances, and nies, Inc., Myrtle Beach, SC, through the Southern the U.S. Environmental Protection Agency has Pine Council, Kenner, LA. Rough carpentry by Voy- implemented the WaterSense® program to label ager Builders, Sun Prairie, WI. high-quality, water-efficient products that make it

22 Research Demonstration House—Second Floor Second Floor Second Floor

Larch Flooring Maple Flooring The flooring in bedroom 3 is nominal 1- by 4-inch The flooring in bedroom 4 is tongue-and-groove and 1- by 3-inch tongue-and-groove larch that birds-eye maple. Individual planks measure ap- was nailed to the subfloor using conventional proximately 2-1/4 inches wide and 3/4 inches thick wood floor installation practices. This flooring is and were installed by nailing the planks to the another example of a useful product that can be subfloor. The flooring was finished in place using manufactured from small-diameter, suppressed- a water-based sealer followed by two coats of a growth trees that must be removed from the for- water-based, semi-gloss finish. This hard maple est to improve forest health and reduce the risk of flooring is extremely durable because it is a resi- catastrophic wildfire. dential version of the flooring this manufacturer Flooring provided by Tricon Timber, St. Regis, MT. installs in athletic facilities such as gymnasiums. Flooring provided by Action Floor Systems LLC, Mercer, WI.

Research Demonstration House—Second Floor 23 Basement

24 Research Demonstration House—Basement Basement Basement

Engineered Wood Products This house was constructed using a wide range of engineered wood products, most of which are vis- ible in the basement. Engineered wood products are manufactured by bonding together lumber, veneers, wood strands, or other forms of wood fiber to produce a larger composite material. The results are products that are more consistently reliable than sawn lumber and are stronger and stiffer. Additionally, engineered wood products can be designed to meet application-specific performance requirements and are engineered Materials supplied by Arch Wood Preserving, to precise design specifications that are tested Smyrna, GA; Biewer Lumber, St. Clair, MI; Hoover to meet national or international standards. They Permanent Wood Foundation Treated Wood Products, Thomson, GA; Midwest are also very resource efficient because they can The basement walls and floor are constructed Timber, Edwardsburg, MI; Osmose Wood Pre- be manufactured using small-diameter trees from of pressure-treated Southern Pine lumber and serving Division, Griffin, GA; Permanent Wood plantations or forest thinning and a wide range of plywood to create a permanent wood foundation Foundations, Inc., Flint, MI; Quality Wood Treat- tree species. ing Company, Prairie du Chien, WI; and Wickes (PWF). The PWF is designed to resist and dis- “Engineered wood products have set new perfor- Lumber Company, Vernon Hills, IL. Prefabrication tribute earth, wind, and seismic forces and resist mance standards by minimizing both resource and by Windsor Homes, Madison, WI. Installation car- decay, mold, and termite attack. The walls consist manufacturing defects while enhancing structural pentry by Elliott Construction, Inc., Middleton, WI. of nominal 2- by 10-inch treated lumber supports integrity.”—Thomas Williamson, Vice President of and nominal 3/4-inch-thick plywood sheathing Quality and Technical (Retired), Engineered Wood with a plastic sheeting vapor barrier between the Systems, APA – The Engineered Wood Association. plywood and the earth. The space between the The engineered wood products used in this house supports is insulated to provide a comfortable, are described next and are on display in the base- energy-efficient living space (see wall cutout). The ment. floor is nominal 1-1/4-inch tongue-and-groove treated plywood that is supported on nominal 2- by 4-inch treated lumber that rests on a bed of crushed gravel covered with a layer of plastic sheeting (see floor cutout). This basement founda- tion was built in freezing temperatures during the middle of winter when construction of a masonry or poured concrete foundation would have been very difficult.

Research Demonstration House—Basement 25 Basement

Glued-laminated timber (glulam) consists of Plywood is a structural panel material made by nominal 2-inch-thick and thinner lumber lamina- bonding together multiple layers of wood veneer, Oriented strandboard (OSB) is a structural tions that are bonded together with waterproof oriented 90° to one another. The veneer cross- panel product made by compressing and bond- structural adhesive. Glulam is commonly used for banding provides strength and dimensional stabil- ing together rectangular-shaped wood strands beams or columns and is engineered so that the ity characteristics that make plywood an excellent (flakes) to form a sheet. Like the veneer in ply- strength and quality of the lumber laminations can construction material. Plywood was invented more wood, the strands are placed in layers that are be varied depending on the specific engineering than 100 years ago and is most commonly used as oriented perpendicular to each other for maximum properties required for the structural application. floor, wall, or roof sheathing. It is typically avail- strength, stiffness, and stability. OSB evolved from Glulam can be manufactured in shapes ranging able in nominal thicknesses of 1/4 to 1-1/4 inches, wafer board in the late 1970s but differs from from straight beams for residential and nonresi- panel widths of 4 feet, and panel lengths of 8, 10, wafer board in that OSB is a structural material dential building applications to complex curved and 12 feet. and the wood strands are oriented, not randomly members for arched roofs and domes. The size Plywood provided by Boise Cascade Corporation, placed. OSB is commonly used as sheathing or as of glulam members is generally limited only by Boise, ID. a component of wood I-joists (see next page). It is transportation and erection restrictions. Typical typically available in nominal thicknesses of 7/16 sizes range from 3-1/8 to 12-1/4 inches wide, 9 to to 1-1/4 inches, panel widths of 4 feet, and panel 72 inches deep, and over 120 feet long. lengths of 8, 10, and 12 feet. Glulam provided by Willamette Industries, Ruston, OSB provided by Tolko Industries LTD, Vernon, BC, LA. Canada.

26 Research Demonstration House—Basement Basement Basement

I-joists are structural components Rim board connects the I-joists together around Laminated veneer lumber (LVL) is made by that are also referred to as I-beams the floor perimeter and fills the space between the bonding together sheets of wood veneer that are because the flanges and web re- sill plate and the bottom wall plate at the base- approximately 0.10 inch thick. Unlike plywood, semble the shape of the letter I. This shape is very ment–first floor interface, and between the top the veneer grain for LVL is all oriented in the same efficient structurally and provides the high bending plate and bottom plate at the first floor–second direction and the material is used for beams or as strength and stiffness characteristics needed for floor interface. In addition to filling the void, rim the flanges of I-joists, rather than a panel product. beams in floor and roof framing applications. The board is an integral structural component that LVL is manufactured in large panels or “billets” that top and bottom flanges are typically dimension transfers both lateral and vertical forces. To func- are sawn to the dimensions needed for specific lumber or LVL; the web is usually OSB or plywood. tion properly, the rim board must match the depth construction applications. It is typically available in I-joists use 36% less wood fiber than solid lumber of I-joists used for floor framing. Rim boards are thicknesses of 1-1/2 to 3-1/2 inches, widths up to joists installed at the same spacing, are very light- manufactured from plywood, OSB, glulam, or LVL 24 inches, and lengths up to 60 feet. weight, and can be easily handled at the jobsite and are available in widths to match I-joist sizes Laminated veneer lumber provided by Willamette without the need for costly handling equipment. and lengths up to 24 feet. Industries, Ruston, LA. They are generally available in flange widths of Rim Board supplied by Willamette Industries, 1-1/2 to 3-1/2 inches, depths of 9-1/2 to 16 inches, Ruston, LA. and lengths up to 60 feet. I-joists supplied by Willamette Industries, Ruston, LA.

Research Demonstration House—Basement 27 Basement

Cellulose Insulation Lumber Connectors Proper insulation is a critical component of a com- fortable and energy-efficient home. It is impor- Lumber connectors are formed metal components tant to have a continuous boundary of insulation that are designed to transmit forces between between the conditioned indoor space and the throughout the house. It is blown in place during wood members. They are attached to the connect- unconditioned outdoor space. This boundary is re- construction, fills all voids in the wall and ceiling ed members with fasteners, such as nails or screws, ferred to as the “building envelope” and consists of cavities, and includes a light water-based adhesive and provide significantly more strength than a the walls, floor, and ceiling or roof. Low insulation to prevent settlement over time. It is also treated connection consisting of fasteners alone. Lumber levels and gaps or voids in the insulation materials with borate to inhibit insect infestation and mold connectors are also much more suitable for trans- can provide paths through which heat and air can growth and to serve as a fire retardant. Cellulose ferring dynamic loads resulting from earthquakes easily flow into or out of the house. Materials used insulation of this type provides an R-value of 20 in or high winds and are required by code in many for insulation are rated according to their ability the nominal 6-inch-thick walls and 38 in the ceilings, locations where this type of loading may occur. to resist heat flow. This thermal resistance rating is which is approximately the same as an equivalent They are made in many different configurations for commonly known as an “R-value.” The higher the thickness of conventional fiberglass batt insulation. various applications, including connections be- R-value of a material, the better it will resist heat tween wood and concrete or masonry. flow. Cellulose insulation provided by U.S. Green Fiber, LLC, Charlotte, NC. Lumber connectors provided by USP Structural As shown in the basement wall cutout and at other Connectors, Montgomery, MN. locations on the first and second floors, cellulose insulation made from recycled newsprint is used

28 Research Demonstration House—Basement Basement Basement

and second floors. As outdoor air exchanges with indoor air, the tracer gas concentration decreases. Researchers are using these measurements to verify the performance of the energy recovery ventilator and to investigate basement humidity. In houses with damp basements, indoor humid- ity levels can be very high, and recent estimates suggest that evaporation from a damp basement can contribute over 40 pounds of moisture per day. Researchers are developing a method, using the tracer gas measurements, to indirectly measure how much moisture enters this house through the basement.

Duct Sealers: Tape and Mastic Tracer Gas Research Station This house has forced-air heating and cooling sys- Equipment is set up in the basement for measur- tems, and ducts are used to distribute conditioned ing the rate at which air is exchanged between the air throughout the house. In a typical house with inside of the house and the outdoors. Some of this ducts, approximately 20% of the air that moves air exchange occurs naturally, through small leaks through the duct system is lost due to leaks, holes, in the walls and ceiling, and is driven by pressure and poorly connected fittings. The result is higher differences caused by the wind and by differences utility bills and difficulty keeping the house com- between indoor and outdoor temperature. Air fortable, no matter how the thermostat is set. leakage through walls can be problematic because it can make a house feel draughty and use more Duct tape, which is commonly gray in color, is a energy for heating in the winter. Uncontrolled air fabric-based tape with rubber adhesive. Despite its leakage may also lead to moisture accumulation name, this type of tape should never be used for inside walls. This house was constructed to be duct sealing because it becomes brittle and com- very air-tight with minimal natural air exchange monly fails (it is also prohibited by several building between the indoor and outside air. To provide codes). The best long-term seal is obtained by us- sufficient fresh air for a healthy living environment, ing professional grade metalized or aluminum tape the house has an energy recovery ventilator. For (shiny tape in the photo) or mastic duct sealing research purposes, the exchange rate between in- compound that is applied around the duct joint door and outside air is measured in different areas with a brush or trowel (tan material in the photo). of the house using an inert tracer gas. To accom- Duct sealer provided by McGill AirSeal LLC, Colum- plish this, the inert tracer gas is initially dispersed bus, OH. through the house at parts-per-billion levels. The gas concentration is then measured using the equipment in the basement through small tubes that are located in multiple rooms on the first

Research Demonstration House—Basement 29 Basement

Hot Water Heater (Conventional) Dehumidifier Reverse Osmosis Water Filter Storage hot water heaters typically heat water with A dehumidifier removes water from the air and Reverse osmosis systems (which include filtration) natural gas or electricity and keep it ready for use lowers the relative humidity during the humid remove most heavy metals and contaminants, use in an insulated tank. They are the most common summer season. Lowering the humidity makes the no electricity, and provide fresh, clean water. In type of water heater in the United States and can air feel cooler and more comfortable, hence the this house, the system is located in the basement, store from 20 to 120 gallons, depending on tank adage “it’s not the heat, it’s the humidity.” Using a next to the water softener. Water is passed through size. A measure of how well a storage hot water dehumidifier also reduces the incidence of mold an initial particle filter that removes silt and large heater converts fuel to heat is the energy factor and fungus growth, expansion and warping of particles, and then passes through an activated (EF), which is typically displayed on a label placed wood furniture, sticking doors and windows, drip- carbon filter that traps other contaminants. Water on the heater exterior. The higher the EF number, ping pipes, and musty odors. By using a dehumidi- then enters the reverse osmosis module un- the more efficiently the water heater uses energy. fier, you can significantly reduce the use of air con- der pressure, allowing only clean water to pass; Electric water heaters have EF numbers between ditioning equipment during the summer season, minerals and other impurities that are too big to 0.75 and 0.95, and gas units are rated between which saves energy. The dehumidifier in this house pass through the membrane are left behind and 0.50 and 0.70. The unit in this house is a high-effi- is ENERGY STAR® qualified. ENERGY STAR® mod- are flushed away. Treated water is finally passed ciency gas model with an EF of 0.60. Compared to els have more efficient refrigeration coils, compres- through an activated carbon filter and is ready for older models, it has better insulation, better heat sors, and fans than conventional models, which use through a small faucet located on the kitchen traps, more efficient burners, and a power vent to means they use 10% to 20% less energy to remove sink. Treated water will not produce a mineral accelerate the venting of combustion gases. Im- the same amount of moisture. In fact, the energy build-up in kettles and coffee makers. A downside provements of this type can have a modest impact saved by an ENERGY STAR® qualified dehumidi- for some users is that reverse osmosis removes on price but increase efficiency by about 7.5%. fier over the life of the unit could power a home fluoride. refrigerator for up to 6 months. Water heater provided by Bradford White Corpora- Reverse osmosis water filter provided by Culligan In- tion, Ambler, PA. Dehumidifier provided by Therma-Stor Products, ternational Company, Northbrook, IL, through Total Madison, WI. Water Treatment Systems, Inc., Madison, WI.

30 Research Demonstration House—Basement Basement Basement

Water Softener GFX The term “hard water” Drainwater refers to water with Heat Recovery high levels of dissolved calcium and/or mag- System nesium. Hard water The GFX (gravity film can be a problem for exchange) drainwater homeowners for the heat recovery system following reasons: reclaims heat from waste water that is • Can cause “scale” to normally lost down form on the inside the drain. The GFX of pipes and water replaces a vertical heaters, which can section of standard significantly reduce flow and heat transfer Tankless Water Heating System drain pipe and can be • Reacts with soap to form a sticky scum and re- used in new con- This tankless water heating system is an electric duces the ability of soap to lather, making wash- struction as well as unit designed to continuously provide water at ing people, dishes, and laundry less productive a retrofit in existing 120°F. Because water is heated only when needed, and there is no high-temperature water storage, • Can lead to galvanic corrosion in the plumbing homes. As hot water the system is very energy efficient. When hot system, where one type of metal will preferen- falls down through water is stored in a large tank and not being used, tially corrode when in contact with another type the GFX, it clings to conventional water heaters still expend energy to of metal the inner surface in a thin film. The heat from this film is transferred to the cold water circulating in keep that water warm. Water reheated in a tank • Requires more energy to heat the copper tubing wrapped around the outside of accounts for 10% to 20% of a household’s annual heating costs. Tankless water heating systems can A water softener can prevent or substantially reduce the drain pipe. Preheated water can then be sup- be used for new construction or as replacements these problems. In a typical water softener, incom- plied to the inlet of the hot water heater, which for conventional hot water heaters. ing water is passed through a resin bed that reduc- can potentially save between 20% and 60% of es the levels of calcium and magnesium to make it water heating costs. Tankless water heating system provided by Micro- “soft.” To remain effective in this process, the resin GFX Drainwater Heat Recovery System provided therm, Inc., Houston, TX, through Marlin Sales, St. bed must be periodically flushed with a saltwa- and installed by Madison Gas and Electric, Madi- Robert, MO. ter brine solution to remove the trapped calcium son, WI. and magnesium. This water softener automatically monitors water quality to maximize efficiency and use the least amount of salt and water necessary to operate the system. Water softener provided by Culligan International Company, Northbrook, IL, through Total Water Treat- ment Systems, Inc., Madison, WI.

Research Demonstration House—Basement 31 Basement

unit near the outgoing conditioned air. The two air streams do not mix, but pass each other separated by thin walls that allow energy transfer between the air flows. In winter, the heat transfer from the warm indoor air to the incoming cold fresh air can recover as much as 77% of the heat energy. Thus, an energy recovery ventilator helps provide a com- fortable, energy-efficient, and noise-free means of exchanging stale, indoor air with fresh outdoor air. Energy recovery ventilator provided by RenewAire LLC, Madison, WI.

Energy Recovery Ventilator STAR® energy-efficiency guidelines set by the U.S. Environmental Protection Agency and the U.S. Most houses built in the past 20 years are tightly Department of Energy. Using ENERGY STAR® ap- sealed to maximize energy efficiency. However, this pliances reduces energy use, which helps prevent tight seal also limits fresh air ventilation, which can global climate change and promotes cleaner air lead to a build-up of moisture vapor and indoor while enhancing the comfort of your home. The air pollutants. According to the U.S. Environmental furnace unit is a gas-fired condensing unit that Protection Agency, concentrations of toxic pollut- employs two heat exchangers to obtain the maxi- ants can be up to 100 times greater inside a home mum heat from the consumed fuel. The furnace than outside, even in our smoggiest cities. Poor is approximately 33% more efficient than conven- ventilation can also lead to stuffy air and a build- tional furnaces that are not ENERGY STAR® quali- up of unpleasant odors, irritating pollutants, and fied, and over 90% of the heat generated during potentially harmful gases such as radon or carbon combustion is captured and delivered inside the monoxide. As houses are built tighter with bet- home. The air conditioning unit is also high ef- ter windows, more insulation, and high efficiency ficiency (compressor is located outside the rear of heating and cooling systems, the need for ad- the house). ENERGY STAR® qualified central air equate ventilation becomes even more important. conditioners such as this have a higher seasonal A tightly constructed home can benefit greatly efficiency rating (SEER) than standard models, from a mechanical ventilation system, such as this Furnace and Air Conditioner which makes them about 14% more efficient than energy recovery ventilator. The system brings in standard models, and they can cut cooling costs fresh outdoor air and expels stale indoor air while As much as half of the energy used in a typical by 30%. home goes to heating and cooling, so making transferring energy between the two. In the sum- Furnace and air conditioner provided by Bryant, smart decisions about this system can have a big mer, warm fresh air is cooled as it circulates in the Syracuse, NY. effect on utility bills and comfort. In this house, the central heating and cooling system meets ENERGY

32 Research Demonstration House—Basement Basement Basement

Automatic Humidifier Air Cleaner The humidifier is attached to the furnace and Three important methods of improving indoor air humidifies air throughout the entire house. It uses quality are source removal, increased ventilation, the speed and precision of a computer to con- and air cleaning. Installed as part of your central tinuously measure, control, and deliver optimum heating and cooling system, a high-efficiency levels of moisture to indoor air during dry, win- electronic air cleaner can help provide the clean- ter months. The advanced computer technology est, healthiest air in every room. The unit cap- measures the outdoor temperature and indoor tures pollutants from conditioned air, before it is humidity over 86,000 times a day and continually distributed to the home, by trapping allergens adjusts indoor humidity to its optimum level. This such as pollen and spores, airborne dust, dirt, eliminates parched, dry air throughout the house and pet dander, as well as illness-causing bacteria and reduces dry throat, dry skin, and static shocks and viruses. Particles entering the air cleaner pass and keeps furniture and other household items through a control electrode, which focuses and from drying out. It also increases energy efficiency intensifies an electrical field generated by ionizing because a home with moisture feels warmer than a wires. The particles are charged in the electri- dry home, even at lower temperature settings. This cal field and are then collected on a grounded unit requires no manual adjustment other than micro-fiber filter. Maintenance for this type of unit setting the desired humidification level using the is minimal and involves annual media replacement control on the first floor. and wiping down of ionizing wires. Automatic humidifier provided by Research Prod- Electronic air cleaner provided by Research Prod- ucts Corporation, Madison, WI. ucts Corporation, Madison, WI

Research Demonstration House—Basement 33 Carriage House

The Carriage House is a 560-square-foot structure that was designed to approximate a large detached garage. It was constructed in 2008 as part of a re- search project in partnership with the Environmental Research Laboratory, University of Arizona, to evalu- ate the potential for potable rainwater harvesting in a cold climate region. Originally, the rainwater harvest- ing storage and filtration system was to be placed in a small outbuilding designed with passive solar heating. As with the Research Demonstration House, it was de- termined during planning that the structure would be expanded to include a platform for additional research and a showcase for sustainable building technologies and energy efficiency. As a result, the Carriage House includes technologies that are capable of providing all energy and water requirements for the Research Dem- onstration House, the Carriage House, and more.

34 Carriage House Carriage House Site Floor Plan

Carriage House—Site Map 35 Outside

Roof The Carriage House roof provides approximately 800 square feet of projected area for rainwater West End Siding harvesting. It consists of standing seam metal pan- The painted lap siding on the west end of the Car- els that are placed on top of nominal 2- by 4-inch riage House is a wood–plastic composite and is the tongue-and-groove decking, rigid foam insulation same formulation as the unpainted salmon colored and oriented strandboard roof sheathing. The se- siding on the east end (see following description of lection of a proper roof type is an important con- Rainwater Harvesting System East End Siding). This siding has been painted with sideration when developing a rainwater harvesting an exterior water-based acrylic primer and paint and system for potable use. Composite, asphalt, and The water harvesting system for the Carriage is part of a research study to evaluate paint perfor- tar roofing materials are not advisable when water House begins with rainwater collection from the mance on the wood–plastic composite. Although harvesting for potable uses because undesirable roof. Rainwater is initially collected in gutters and wood–plastic composite siding is a uniform color volatile organic components can leach from the is directed to downspouts located at the northeast throughout and typically does not require painting, shingles into the rainwater. and southwest corners of the building. The down- spouts are provided with angled screens to divert this research is being conducted to develop recom- Roofing by McElroy Metal, Inc., Bossier City, LA, and leaves and other large debris before it enters the mendations when painting is necessary for color or installed by Madison Sheet Metal LLC, Madison, WI. rainwater collection system. Rainwater from the other reasons. southwest corner downspout is currently not con- Siding supplied by Teel Global Resource Technologies, tributing to the rainwater collection as it is being Baraboo, WI. evaluated for cold weather performance. Rainwater harvesting research in cooperation with the Environmental Research Laboratory of the Uni- versity of Arizona, Tucson, AZ.

36 Carriage House—Outside Outside Outside

closed. Whenever the air near the ceiling is warmer than near the floor, a ceiling paddle fan automati- cally turns on to mix the air. Windows provided by Andersen Windows, Bayport, MN.

Passive Solar East End Siding The passive solar sunspace on the south side of Siding on the east side of the Carriage House is the Carriage House collects solar radiation on part of a research project to evaluate the per- sunny winter days to maximize solar heating. Un- formance of unpainted wood–plastic composite like the windows in the Research Demonstration lap siding. Two different formulations are being House, which are specially coated to reflect infra- Photovoltaic Panels evaluated as denoted by the two siding colors. red and ultraviolet radiation, the 168 square feet Instrumentation includes strain gages and ther- Eighteen polysilicon photovoltaic panels mounted of clear glass double-pane sliding doors allows mocouples to monitor dimensional changes in the on the south-facing roof generate electricity from infrared, visible, and ultraviolet solar radiation to siding due to temperature and moisture variations. sunlight. Each panel provides 208 watts of direct pass through. The wall behind the glass is painted Change in the siding color due to solar ultraviolet current (DC), for a total of 3,744 watts. The panels black to improve heat collection in the sunspace. light is also being evaluated. will generate approximately 3,500 watts of alter- A wall painted a light color would reflect the solar nating current (AC) power when operating at full Siding supplied by Teel Global Resource Technolo- radiation back through the glass and minimize capacity. Annually, this equates to 5,500 kilowatt gies, Baraboo, WI, and Strandex Company, Madison, the heating effect. Windows in the black wall al- hours (kWh) of electricity, which is sold back to WI. low daylight in and provide some winter heating Madison Gas and Electric (MG&E), the local power due to the lower angle of the sun. When the air company. At a typical winter consumer use rate in the narrow (10-inch-deep) sunspace is warmed of approximately 25¢ per kWh, this amounts to above the air temperature in the Carriage House, $1,375 per year of electric power. an electronic control circuit activates a fan and the warmed air is blown into the Carriage House. Photovoltaic panel system supplied and installed Cool air is drawn into the sunspace through vents by Wisconsin Power Control with support from near the floor on each end. When the sunspace is Wisconsin Focus on Energy and Madison Gas and cooler than the Carriage House, interior backdraft Electric Company, all of Madison, WI. dampers on the fan opening and vents remain

Carriage House—Outside 37 Inside

Structure Framework The structural framework of the Carriage House Rainwater Storage and Filtration consists of 6-inch-diameter round wood posts and trusses that are built from small-diameter logs ob- Rainwater First Flush Tank Incoming water from the first flush tank flows into a tained from forest thinnings in the U.S. Southwest. 2,400-gallon cistern, which is located below the Car- Incoming rainwater from the downspout enters riage House floor and is accessible through an iron The individual members are interconnected with the blue barrel in the corner of the Carriage 1/4-inch-thick bolted steel plates. Although round access hole cover. If the cistern becomes full, excess House, which is called a first flush device. The water flows through an overflow tube and into a drain wood structural members are economical and purpose of the first flush device is to remove are very efficient structurally, they are not com- field located on the south side of the building. In debris and contaminates from the initial water preparation for use, water from the cistern is drawn monly used for construction, where sawn lumber flow before it enters the storage tank, which is has historically been the material of choice. One and pressurized using a standard water pump and called a cistern. This is important in rainwater pressurization system and passes through a series reason for this has been a lack of efficient struc- harvesting to prevent clogging, reduce main- tural connections to transfer loads between the of filters. The first two filters remove small particles, tenance of the storage and filter systems, and and then a charcoal filter removes residual minerals members. This has been a research focus at FPL, reduce health hazards from mosquitoes, bird and the bolted plate connectors are a result of this and metals such as lead. The filtered rainwater finally droppings, and other sources. When water passes through an ultraviolet purifier that disinfects research. Additional structural members include flows from the downspout, it is initially diverted glued-laminated timber beams that run the length the water and kills any remaining microorganisms. to the first flush tank. When the specified level The purified water is then piped to the Research of the building and laminated tongue-and-groove of water in the tank is reached, the remaining decking for structural roof members. Both of these Demonstration House where it is connected with back water is diverted to the cistern for storage. The flow prevention to the water supply. Valves are also products are made from Arizona ponderosa pine water and debris in the first flush tank is then obtained from forest thinnings. The walls between provided so that either disinfected rainwater or water drained slowly in preparation for the next rain- from the municipal supply can be used. the posts are conventional framing with fiberglass fall. Both the volume and rate of drainage can batt and rigid foam insulation and oriented strand- be adjusted for different site conditions. It is interesting to note that during excavation for the board exterior wall sheathing. Carriage House cistern, a cistern from the original Timber framing and decking provided by American farmhouse on the site was uncovered. Two bricks West Structures, Show Low, AZ, with construction from the original cistern are on display. by Richter Construction, Arena, WI, and Four Bears Rainwater harvesting research in cooperation with the Construction, Madison, WI. Environmental Research Laboratory of the University of Arizona, Tucson, AZ. 38 Carriage House—Inside Inside Inside

Inverter water and can also be used to dry fuel pellets. The The photovoltaic panels on the roof are connected combustible gases are cooled in a heat exchanger to an inverter that converts the DC electricity and are used to power an electric generator. In this generated by the panels to AC electricity typically unit, approximately 20% of the available energy from the wood fuel is used to produce electricity, used for household applications. This electricity BioMax® 5 is then routed to MG&E, the local electric utility and 80% goes to heat. This unit is actually more company. MG&E provides a separate buy-back The BioMax® 5 generates heat and electricity complex than the larger units because it stores meter for this “grid tied” photovoltaic system. The using forest biomass. The unit on display in the electric power in batteries. The larger BioMax® meter runs backward when the photovoltaic ar- Carriage House is a research and demonstration units do not have batteries and operate on a de- ray is generating and supplying electricity to the project involving FPL, the U.S Department of En- mand basis. utility, where the buy-back credit is double the ergy, National Renewable Energy Laboratory, and Due to the experimental nature of this system, an residential consumer electricity purchase rate. Community Power Corporation. BioMax® units are exhaust fan has been installed in the cupola of the currently available in sizes ranging from 5 to 100 Inverter supplied and installed by Wisconsin Power Carriage House in the event of smoke discharge kW. This 5-kW BioMax® 5 unit provides power to Control with support from Wisconsin Focus on into the space. the Research Demonstration House and Carriage Energy and Madison Gas and Electric Company, all House and is one of only three units of this size BioMax® 5 provided by U.S Department of Energy, of Madison, WI. that were developed to demonstrate the technol- National Renewable Energy Laboratory, and Com- ogy for small-scale applications. munity Power Corporation. Operationally, the BioMax® 5 uses wood pellets that are automatically fed into the unit, where they combust in a gasification cylinder at approximately 1700°F. This produces heat and combustible gases. The heat is used for heating indoor spaces and/or

Carriage House—Inside 39 Participating Organizations

Action Floor Systems LLC, Mercer, WI, Composite Panel Association, Leesburg, VA, Leviton Mfg. Company Inc., St. Charles, IL, www.actionfloors.com www.pbmdf.com www.leviton.com Alpine Engineered Products, Pompano Beach, Coyle Carpet One, Madison, WI, LP Corporation, Huntersville, NC, FL, www.alpeng.com www.coylecarpetonemadison.com www.lpcorp.com/smartside American TV, Appliance & Furniture, Madison, Craftmade Company, Coppell, TX, Madison Gas and Electric, Madison, WI, WI, www.americantv.com www.craftmade.com www.mge.com American West Structures, Show Low, AZ Culligan International Company, Northbrook, IL, Madison Sheet Metal LLC, Madison, WI (no website available) www.culligan.com (no website available) Andersen Windows, Bayport, MN, Design Basics, Omaha, NE, Mannington, Salem, NJ, www.andersenwindows.com www.designbasics.com www.mannington.com APA – The Engineered Wood Association, DuPont Nonwovens – Tyvek, McElroy Metal, Inc., Bossier City, LA, www.apawood.org www.dupont.com www.mcelroy.com Arch Chemicals, Inc., Smyrna, GA, Florida Tile Industries, Lakeland, FL, McGill AirSeal LLC., Columbus, OH, www.archchemicals.com www.floridatile.com www.mcgillairseal.com Barnett Millworks, Inc., Theodore, AL, Fort Ord Reuse Authority, Marina, CA, McKenzie Forest Products, Springfield, OR www.barnettmillworks.com www.fora.org (now Swanson Group), www.swansongroupinc.com Biewer Lumber, Lansing, MI, Four Bears Construction, Burlington, WI www.biewerlumber.com (no website available) Microtherm, Inc., Houston, TX, www.seisco.com Boise Cascade Corporation, Boise, ID, Future Foam, Middleton, WI, www.bc.com www.futurefoam.com Midwest Timber, Edwardsburg, MI, www.midwesttimber.com Bradford White Corporation, Ambler, PA, Georgia-Pacific Corporation, Atlanta, GA, www.bradfordwhite.com www.gp.com Mitsubishi Electrical, www.mitsubishielectric.com Bryant, Syracuse, NY, Graber, Middleton, WI www.bryant.com www.graberblinds.com New South Companies, Inc., Myrtle Beach, SC, www.canfor.com/products/wood/newsouth/ Cardinal Heating & Air Conditioning, Inc., Hoover Treated Wood Products, Thomson, GA, Sun Prairie, WI, www.frtw.com Osmose Wood Preserving Division, Griffin, GA, www.cardinalhvac.com www.osmosewood.com Isthmus Lighting, Madison, WI CasMont Industries, Inc., Louisville, KY (no website available) Overhead Door Corporation, Madison, WI, (no website available) www.overheaddoor.com Jefferson State Forest Products, Hayfork, CA, Community Power Corporation, Littleton, CO, www.jeffersonstateproducts.com Pacific Wood Laminates, Inc., Brookings, OR, www.gocpc.com www.pacificwoodlaminates.com Kohler Company, Kohler, WI, www.kohler.com

40 Participating Organizations Participating Organizations Participating Organizations

Permanent Wood Foundations, Inc., Flint, MI Square D, Palatine, IL, Vermont Castings, Bethel, VT (no website available) www.schneider-electric.us www.vermontcastings.com Prest-On Company, Hot Springs, AR, Stephenson Tree Care, Inc., Madison, WI, Voyager Builders, Sun Prairie, WI www.prest-on.com www.stephensontree.com (no website available) Progress Lighting, Spartanburg, SC, Strandex Company, Madison, WI, VT Industries, Holstein, IA, www.progresslighting.com www.strandex.com www.vtindustries.com ProSource Wholesale Floorcovering, Madison, Teel-Global Resource Technologies, Baraboo, WI, Watershed Research & Training Center, Hayfork, WI, www.prosourcefloors.com www.teel-grt.com CA, www.thewatershedcenter.com Quality Cabinets, Duncanville, TX, Temperature Systems, Inc., Madison, WI, Weekes Forest Products, Inc., St. Paul, MN, www.qualitycabinets.com www.tsihvac.com www.weekesforest.com Quality Wood Treating Company, Teton West Lumber Company, Weyerhaeuser, Hot Springs, AR, Prairie du Chien, WI, www.tetonwest.com www.weyerhaeuser.com (no website available) Therma-Stor Products, Madison, WI, Whirlpool Corporation, Benton Harbor, MI, RenewAire LLC, Madison, WI www.thermastor.com www.whirlpoolcorp.com www.renewaire.com Tolko Industries LTD, Vernon, BC, Canada, Wickes Lumber Company, Vernon Hills, IL Research Products Corporation, Madison, WI, www.tolko.com (no website available) www.aprilaire.com Total Water Treatment Systems, Inc., Madison, Willamette Industries (now Weyerhaeuser), Richardson Wood Preserving, DePere, WI, WI, www.total-water.com Ruston, LA, www.richardsonbrothers.com www.weyerhaeuser.com Tricon Timber, St. Regis, MT Richter Construction, Arena, WI (no website available) Windsor Homes, Madison, WI (no website available) (no website available) U.S. Department of Energy’s National Renew- Seisco, Houston, TX, able Energy Laboratory, Golden, CO, Wisconsin Energy Star Certification, Madison, WI www.seisco.com www.nrel.gov www.focusonenergy.com Shaw Floor Alliance, Madison, WI U.S. Green Fiber, LLC, Charlotte, NC, Wisconsin Flooring Center, Fitchburg, WI, (no website available) www.greenfiber.com www.floor360.com Sherwin-Williams, Strongsville, OH, United Brick and Tile, Madison, WI, Wisconsin Green Building Alliance, Milwaukee, WI www.sherwin-williams.com www.unitedbrickandtile.net www.wgba.org Somerset Wood Products, Somerset, KY, University of Arizona, Tucson, AZ Wisconsin Power Control, Madison, WI, www.somersetwood.com www.arizona.edu www.wipowercontrol.com Southern Pine Council, Kenner, LA, USG Corporation, Chicago, IL, www.southernpine.com www.usg.com Springs Window Fashions, Middleton, WI, USP Structural Connectors, Montgomery, MN, www.springswindowfashions.com www.uspconnectors.com Participating Organizations 41