Winchester/Camberley Homes New Construction Test House Design, Construction, and Short-Term Testing in a Mixed-Humid Climate D. Mallay, J. Wiehagen, and A. Wood NAHB Research Center Industry Partnership October 2012 NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, subcontractors, or affiliated partners makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. Available electronically at http://www.osti.gov/bridge Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 phone: 865.576.8401 fax: 865.576.5728 email: mailto:[email protected] Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 phone: 800.553.6847 fax: 703.605.6900 email: [email protected] online ordering: http://www.ntis.gov/ordering.htm Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste Winchester/Camberley Homes New Construction Test House Design, Construction, and Short-Term Testing in a Mixed-Humid Climate Prepared for: The National Renewable Energy Laboratory On behalf of the U.S. Department of Energy’s Building America Program Office of Energy Efficiency and Renewable Energy 15013 Denver West Parkway Golden, CO 80401 NREL Contract No. DE-AC36-08GO28308 Prepared by: D. Mallay, J. Wiehagen, and A. Wood NAHB Research Center Industry Partnership 400 Prince George’s Blvd Upper Marlboro, MD 20774 NREL Technical Monitor: Stacey Rothgeb Prepared under Contract No. KNDJ-0-40335-00 October 2012 iii [This page left blank] iv Contents List of Figures ............................................................................................................................................ vi List of Tables .............................................................................................................................................. vi Definitions .................................................................................................................................................. vii Executive Summary ................................................................................................................................. viii 1 Introduction ........................................................................................................................................... 1 1.1 Overview ..............................................................................................................................1 1.2 Background ..........................................................................................................................1 1.3 Goals ..................................................................................................................................2 2 Design Development ............................................................................................................................ 3 2.1 Design Process and Energy Simulations..............................................................................3 2.2 Cost Analysis .......................................................................................................................3 2.3 Energy Solutions Package ....................................................................................................3 3 Thermal Envelope ................................................................................................................................. 7 3.1 Framing ................................................................................................................................7 3.2 Air Sealing ...........................................................................................................................9 3.3 Insulation and Fenestration ................................................................................................12 4 Systems ............................................................................................................................................... 13 4.1 HVAC System ...................................................................................................................13 4.2 Plumbing ............................................................................................................................16 4.3 Lighting and Appliances ....................................................................................................16 5 Implementation ................................................................................................................................... 17 5.1 Framing ..............................................................................................................................17 5.2 Air Sealing and Insulation .................................................................................................18 5.3 HVAC ................................................................................................................................20 6 Testing ................................................................................................................................................. 22 6.1 Test Plan.............................................................................................................................22 6.2 Infiltration Testing .............................................................................................................23 6.3 Duct Leakage Testing ........................................................................................................24 6.4 HVAC Equipment Testing (Startup) .................................................................................25 6.5 HVAC Duct Distribution Testing ......................................................................................25 6.6 Ventilation Testing.............................................................................................................25 7 Gaps and Lessons Learned ............................................................................................................... 27 7.1 Overview ............................................................................................................................27 7.2 Framing ..............................................................................................................................27 7.3 Air Sealing .........................................................................................................................27 7.4 HVAC ................................................................................................................................27 7.5 Plumbing ............................................................................................................................28 7.6 Energy Simulations and Cost Effectiveness ......................................................................28 7.7 Quality Assurance ..............................................................................................................28 8 Summary ............................................................................................................................................. 29 8.1 Overview ............................................................................................................................29 8.2 Next Steps ..........................................................................................................................30 References ................................................................................................................................................. 31 Appendix A Energy Simulations......................................................................................................... 32 Appendix B Complexity of the Home’s Thermal Boundaries .......................................................... 35 v List of Figures Figure 1. Winchester/Camberley NCTH .................................................................................................... 1 Figure 2. Advanced wall framing ............................................................................................................... 4 Figure 3. Supply trunk through floor joists and central duct chase ...................................................... 5 Figure 4. Floor framing ............................................................................................................................... 8 Figure 5. Wall panels .................................................................................................................................. 8 Figure 6. Continuous drywall