Why It Pays To Make Your Building Projects Lean and Green 

As consumers in nearly every age and demographic category become more aware of and committed to environmentally conscientious practices in business as well as their personal lives, the benefits for businesses of making Leadership in Energy and Environmental Design (LEED) certification a priority cannot be ignored. For those of us in the building industry specifically, beyond the many wonderful benefits to the earth, there are also numerous advantages for your business and your bottom line. 

LEED Benefits: Reductions

Typically, the most significant financial impact builders of LEED-certified structures realize is the energy efficiency. When constructed with efficient heating and cooling that minimizes energy and indoor/outdoor water usage, buildings can average an energy consumption reduction by 30-60%. Buildings that achieve up to 30% efficiency may qualify for basic LEED certification, with LEED Platinum-level certifications requiring 50-60% efficiency. Silver and Gold certifications require 30-47% and approximately 48%, respectively. Obviously, reduced energy use means reduced energy bills – often among the largest expenses in operating a building. 

Further reducing operating costs, most LEED-certified buildings average 15-20% lower maintenance costs than traditional commercial buildings, and even those that are retrofitted to improve green status can reduce operation costs by nearly 10% in one year. 

LEED Benefits: Increases

Not all benefits are by way of reduction however; LEED certification can also lead to increases: an average of 10% or greater increase in the value of the property, increased resale value, and an increase in employee satisfaction and overall health – which means increased productivity, fewer employee sick days, greater success with recruitment and retention, and more. 

According to Mahesh Ramanujam, president and CEO of the U.S. Green Building Council (USGBC), “Employees know that green building programs like LEED help companies to develop responsible, sustainable, and specific plans for green energy, water, waste, transportation and many other factors accountable for the human experience.” Additionally, the USGBC states that LEED buildings are linked to improved productivity, and health and wellness. In a study conducted by the organization, results showed that people’s decisions were influenced by whether or not the workplace was in a LEED-certified building, and that more than 90% of employees working in a LEED-certified building report job satisfaction. 79% of respondents say they would choose a job in a LEED-certified building over a non-LEED building.  

At Ceco, we’re proud to manufacture the metal building products that can help you achieve your LEED certification and establish your company among the leaders in creating a healthier earth and future through sustainable building practices, as well as position your business for greater success. 

Metal panels and roof systems are among the most effective building materials in improving efficiency, sustainability, and longevity. When you build with metal, you can expect overall higher performance in key areas that are used to determine your building’s LEED certification ranking, especially in Sustainable Sites, Energy and Atmosphere, Materials and Resources, and Indoor Environmental Quality categories, with indirect benefits in the Heat Island Effect and Water Efficiency categories.  

General Ways Metal Building Materials Help Improve LEED Ranking

Below are some general ways metal building materials can help improve your ranking. For specific benefits of Ceco products and how they can help you achieve your desired LEED certification, talk to a Ceco representative. 

• Cool metal roofs and coatings meet designated initial and three-year aged Solar Reflectance Index values for steep and low slope roofs in the Heat Island Effect category 
•  The minimal staging areas of prefabricated metal building systems earn points in the Site Development category 
• The effective rainwater management of metal building systems contributes to ranking in the Water Efficiency category 
• Metal building systems have high insulating value and thermal performance, supporting smaller HVAC systems and reduced electrical loads – all contributing factors in theOptimize Energy Performance category 
• Metal roofs and facades support windows and skylights, as well as PV panels and solar thermal systems, all contributing indirectly to higher ranking in the Renewable Energy Production category 
• The combined optimized environmental performance as well as adaptive reuse of metal products and materials can help with higher ranking in the Materials and Resources category, with indirect benefits also possible from metal construction’s focus on Building Life Cycle Impact Reduction, Whole-Building Life-Cycle Assessment, Building Product Disclosure and Optimization, and Sourcing of Raw Materials. The significantly smaller waste of metal building systems in Construction and Demolition Waste Management can also help add points in this category. 
• Metal walls and roofs that meet Low-Emitting Materials standards can increase the number of points earned in the Indoor Environmental Quality category 

Final Notes on LEED Certification

Of course every building project is different, based on client needs, building location, intended use, budget, and a variety of other factors. But with a little creativity and commitment to the long-term outcome of building practices, we can all work together to make a difference that leads not only to better quality buildings, but a better world for everyone for generations to come. 

Protecting investments in aircraft from weather and ultraviolet light, as well as making them easy to access and work on, has driven many in the aviation industry to seek out the best ways to meet their needs and budget. Whether the requirement is a small, simple hangar or a large, complex, multi-unit facility,  a pre-engineered steel building is an ideal solution because it’s custom designed for specific project needs, including:

• Type and number of aircraft that will be stored in the hangar now and in the future. (This includes clear span requirements, tail heights, turning radii of tow vehicles used to move aircraft, and dimensions of lifting, rolling, bi-fold, or stacking leaf hangar doors.)
• Type of maintenance that will be performed in the facility: airframe and/or engine repair, systems repair, battery services, and interior finishes repair.
• Energy efficiency, including temperature and humidity control.
• Fire protection and alarm devices.
• Office, lounge, and administrative areas.
• Warehouse space.
• Aesthetics to reflect the aviation company’s image.

Metal buildings have been used very successfully in aviation facilities such as standalone and multi-unit projects, private and commercial hangars, and T-hangars, as well as in storage, maintenance, and repair hangars. Industry estimates indicate that engineered building projects take one-third less time to construct than traditional building projects, allowing owners and users to occupy the building sooner. An engineered steel building can also be designed to easily accommodate future expansion.

Aviation Case Study: As an example of how this can all come together, here is an excellent case study

Project: Hangar 19
Location: Fargo, North Dakota
Architect and General Contractor: Olaf Anderson Construction, Fargo, ND
Ceco Products Used: Double-Lok®, PBC Corrugated Wall Panels, AVP Wall Panels

The Project: In the fall of 2017, Olaf Anderson, Inc. of Fargo, North Dakota broke ground on the Hangar 19 project. Located at Hector International Airport, a civil-military public airport in Cass County, this private hangar is owned by a private company. Hector International Airport is the busiest airport in North Dakota with almost 845,000 passengers passing through in 2018 alone, and is also home to Fargo Air National Guard Base, located adjacent to the airport.

The Problem: The luxury of owning or renting a private plane includes having proper aviation storage space as well as a comfortable, stress-free experience. On average, Fargo sees snowfall 6 months of the year, and freezing weather is just as common. Therefore, it was important that private plane owners and renters should not have to brave these conditions while waiting for their aircraft. The benefits of Hangar 19 would come with certain amenities including storage space, a heated garage for vehicles, office space, a lobby, and a lounge area.

The Solution: Olaf Anderson, both the architect and general contractor, was brought on board to design and construct the facility for what would become known as Hangar 19. Anderson is a well-known design-build general contractor in North Dakota, offering an extensive range of capabilities, and is a longtime Ceco builder. He recognized that metal buildings are the most economical way to get large spans for hangar space as well as accommodate large hangar doors.

Anderson chose a Ceco single-slope clear span frame to maximize space for aircraft. In addition, a mezzanine was incorporated into the design with private office space located on both the first and second floors. For the roof, 25,240 sq. ft. of the Double-Lok^® standing seam roof system in Galvalume^® was used. For the exterior, Signature^® 200 Galvanized horizontal PBC corrugated wall panels and 20,000 + sq. ft. of AVP wall panels in Signature^® 200 Burnished Slate were incorporated along with coordinated stonework, which was subcontracted to Sperle Masonry, Inc. of West Fargo, ND.

A particularly impressive feature of this project included an 85 ft. jack beam (for comparison purposes, keep in mind that a normal size jack beam is 60 ft). This larger beam allowed Olaf Anderson to install a massive 80 ft. hangar door. The 85 ft. jack beam also allows for 90 ft. of building frame and currently carries two frames. The hangar owner asked that the possibility for another addition onto the hangar be included in the design should the need arise in the future for expansion.

The Results: Currently, Hangar 19 can accommodate anywhere from 18 to 20 planes, depending on their size. A 34,000 sq. ft. addition to the north of the facility has been allowed for in the design with a more massive hangar door and additional plane storage.

To find out more about selecting the best metal building options for an aviation building that you are involved with, see the Ceco website or contact your local Ceco representative.

The standing seam metal roof is a very popular roofing solution due to its durability, water-tightness, relative simplicity, and clean appearance. While the standing seam, which is created by forming two adjacent metal roof panels together, contributes to all of these traits, some people may not realize that it also simplifies the attachment of other items to the roof. The most common and effective means to attach anything to a standing seam metal roof is to use an ingenious piece of hardware known simply as a seam clamp.

What are seam clamps?

These are engineered and fabricated small cubes of stainless steel or aluminum that are designed to be mechanically attached directly to the standing seams in a metal roof. They do that with a round-point set screw in the clamp that squeezes and dimples the standing seam for a true mechanical attachment. This approach is truly non-invasive since it does not penetrate or compromise the integrity of the metal in any way and therefore keeps all roofing warranties intact. Once secured onto the standing seam, then the seam clamp is the base for threaded bolts or screws that fit into specific locations on the clamp. From there, specific hardware can be secured to attach a variety of additional items. Specifically, seam clamps have been used for decades on metal roofing to secure accessory items such as snow retention systems, fall protection devices, HVAC equipment, lightning protection, satellite dishes, and even rooftop service walkways.

How do they work with solar panels?

One of the biggest current uses of seam clamps is for the connection of solar photovoltaic (PV) panels to a metal roof. On many roof-mounted PV systems, the use of rails or some similar component may be needed to support the PV panels. By using seam clamps with customized interface hardware designed to connect directly to the solar panels, the standing seams of the roof act as the rails. Eliminating the use of the rails and using the seam clamps means the installation is easier and the cost is reduced notably, both in terms of material and labor.

Why put solar panels on a metal roof?

Solar systems are typically warranted 25 years for power production, but the real service life of the modules can be 40 years or more. Hence when mounting the PV system, the building designer or owner needs to be sure that the roof underneath it has a comparable life. Metal roofing is a very good match since it will last as long or longer than the PV panels. A roof with a shorter life will require removal of the PV to replace the roofing and then a reinstall of the PV at a high cost.

How many seam clamps are needed on a roof?

Some seam clamp manufacturers have independently tested their product in combination with literally every standing seam metal roofing system on all of the available metal gauges that are on the market. As such, very specific information can be provided on things like loading capability, wind uplift resistance, etc. for the seam clamps. With that information, combined with the roofing and solar panel information, an engineer can calculate the needed spacing and locations of seam clamps. Those calculations will take into account the specific design wind speed and wind uplift potential for the project location. It will also take into account the specifics of the building structure and the internal structure of the solar panels. In some cases, locations such as perimeters and corners of groups of solar panels (called an array) may require more frequent spacing while in the field of the array, the spacing may be less. Ultimately, the best location and spacing of seam clamps is determined and the proper quantity identified. It is worth noting that when engineered in this manner, the most common mode of failure is that the module itself fails under windy conditions, rather than seam clamp attachment.

What maintenance is needed on seam clamps?

Virtually no maintenance is required. All of the clamp designs are not friction connections, they are mechanical interlocks, so loosening is rarely, if ever, an issue. We have noted that the set screw dimples the standing seam and compresses it to make a mechanical interlock. In addition, locking head screws, bolts, and nuts all with serrations that are directional allow the hardware to be seated but not unscrew, thus holding everything permanently in place. Since all of the metal is either stainless steel or aluminum, there is no concern of rusting or corrosion.

Where can I learn more?

To learn more specifically about seam clamps and how to use them to mount solar panels on a standing seam metal roof, visit the website of the leading manufacturer of seam clamps known as S-5! To learn more about standing seam metal roofing and metal buildings, contact your local Ceco representative.

Content for this article was provided by Rob Haddock, Founder and CEO of S-5!®

Never in our lifetime has it been more evident than now that design and construction teams are incorporating so many different elements into projects. Customers are increasingly requesting more features and benefits to keep up with changing codes and their own personal requirements. It is our job as the suppliers, builders, contractors and architects to deliver on those needs.

There is something to be said for a tastefully constructed building that brings together many elements. That is quite true for the City of Greenville Public Works Campus project. Not only was sustainability an important factor for the campus, so was the ability for it to be economical and multi-purposeful.

Sustainability

A sustainable building delivers on energy efficiency, reducing waste, conserving natural resources and optimizing performance. The green movement is at an all-time high in almost every industry today therefore, it’s pivotal that companies provide a built-in sustainable strategy. Ceco was able to help achieve that with this project. The roofing system for the campus was comprised of CFR insulated metal roof panels in Kynar Polar White. The white roof reinforces sustainability by being highly reflective of the sun and reducing solar heat gain. The CFR IMP also offers a superior R-30 value, ultimately enhancing energy performance. The building’s walls are comprised of the 7.2 Insul-Rib™ and Striated insulated wall panels and with a R-21 value, these IMP’s provide another effective measure of energy efficiency. Another benefit of Ceco’s products is that they are virtually 100% recyclable, therefore, contributing to the reduction of waste, another huge sustainability benefit.

Economical

Frankly, people want the best value for their dollar. The benefit of low maintenance and low operating costs of metal building’s mean optimization of economic performance throughout the building’s life cycle. Not only are customers looking for value, but they are also looking for short turn around times (within reason). A huge motive for the City of Greenville choosing to build with metal was a faster erection schedule than conventional building materials. Both features of a custom metal building system boded well for the City whose project ultimately came in under budget and finished ahead of schedule.

Multi-Purposeful

Efficiency is important to every company. Bringing together different factions of the business to all be centrally located and housed under one roof was an important ask of the City of Greenville. Ultimately, the end project just did this. The campus contains four buildings for fleet services, operations and administration, a fuel island and truck wash. All of these integral parts of the business now have a home from which to conduct business efficiently.

For more information about Ceco’s City of Greenville project, visit our case study page.

Metal buildings come in all shapes and sizes with color options that are almost limitless. The profiles, of pre-engineered metal buildings, are also extensive. With insulated metal panels that now resemble pre-cast concrete or stucco, you may mistake a metal building for being built with some other material. Don’t judge a book by its cover as appearances can be deceiving.

The Evolution of a Steel Building

Metal buildings first came on the market in the late 1700’s and began surfacing across the textile industry. During WWII, metal buildings began being used in large numbers for airplane hangars and Quonset huts. Steel buildings have traditionally been thought of as a plain, gray, boring box structure like the manufacturing plants or warehouses you see that line the highway. While manufacturing plants and warehouses are still often made of steel and metal, they are anything but boring and certainly not limited to one color choice. Gone are the days when a metal building was restricted to look like just a square metal box. Today, metal buildings are used in a vast number of industries for nearly any purpose you can think of.

Metal Building Colors

Colors are ever-changing and depending on the industry, go in and out of popularity relatively quickly. However, across the metal building industry, owners are requesting what were once unfathomable color choices for their buildings. Whether the main focus or accented, colors are now a huge driving force behind the design of a building. Manufacturers have adjusted and now offer expansive color options. With choices that span the color spectrum, the reality is that color is being tastefully incorporated into the metal building design quite frequently nowadays.

The Advancement of All Things Technology Driven, Green and Sustainable

Metal buildings have evolved with time, technology, building codes and the industry. Undoubtedly, technology has revolutionized how we do business today and going green isn’t slowing anytime soon. Customers expect better tools everyday and the metal building industry is shifting to keep up with the technology advancements. Sustainability is on the lips of everyone in the metal building industry. The green movement has set an unprecedented change in what customers are asking for and expect manufacturers to supply…enter stage right: insulated panels and higher R-values. The benefits are evident and designing with IMPs has become increasingly important across the industry.

It’s important to be open to the idea of what a modern metal building can look like for you. Learn more about the metal buildings we’ve worked on by viewing our project gallery or contact your local Ceco representative to see how we can turn your vision into reality.

Energy conservation in buildings has become increasingly important in recent times making building owners, designers and constructors all quite interested in finding reliable, durable and proven solutions for well insulated wall and roof systems. Insulated metal panels (IMPs) offer just that in a complete, finished, coordinated product with excellent thermal performance, inherent cost-efficiencies and a variety of options.

What are IMPs?

Insulated metal panels consist of two single-skin metal panels and a foamed in-place core. The inner and outer faces of the panels can be lightly profiled with vertical striations of varying degrees, delivering a subtle pattern that can appear virtually flat. In addition, there are other options for the exterior face appearance. Some architectural panels are completely flat and smooth creating a sleek, modern, look. Others come in textures that resemble stucco or precast concrete. If you are looking to add versatility to the building, certain IMPs can be installed both horizontally and vertically depending on the panel.

Where are they used?

IMPs are a superior choice for both new and retrofit construction. These panels function very well and provide great design versatility for all types of architectural, commercial, agricultural, institutional, industrial and cold storage buildings.

What is the reason for the foam core?

The foam core provides two important characteristics to the panel. Structurally, the metal and foam composite construction creates a strong rigid panel, increases the span capacity compared to metal panels alone and thus reduces secondary structural steel components. Thermally, the foam provides high levels of insulation for the roof and walls of a building. The degree of insulation can be selected based on the thickness of the foam, which generally ranges from 2 to 6 inches. The thicker the foam, the higher the insulating R-value.

What is their thermal performance like?

IMPs have excellent insulating capabilities. The rigid foam achieves approximately R-7 or more per inch of thickness. That is almost twice the R-value per inch of batt and blown insulation. Hence, IMPs can provide enhanced energy performance in a thinner profile than other types of insulation. Further, in light of recent prescriptive energy code changes, IMPs are an elegant means to provide “continuous insulation” outside of the primary and secondary structural steel. Since the inner and outer steel faces typically don’t come in contact with each other, the insulation provides a continuous thermal barrier around the building exterior that is not compromised by the structural elements. Instead, the panels have formed edges designed to interlock so that the insulating properties remain continuous across panel joints.

How are the panel joints sealed?

IMPs are sealed at the side laps and all perimeter boundaries. Generally speaking, because of the nature of the joinery, it is easier to get a good seal in place with IMPs given their relative simplicity (i.e., putting the two pieces together with the sealant) compared to other wall or roof assemblies. IMPs require great attention, though, in terms of air and vapor sealing—aspects largely controlled by the installers on a given project. As an example, vapor sealing in cold climates or similar applications is critical to the overall soundness of a building. Consider the damage a wall or roof could incur if moisture seeps into a panel and becomes trapped; if it freezes, it could push panels out of alignment. This would result in not just an unattractive aesthetic, but a performance failure as well. In order to be effective, all sealant and caulking must be fully continuous.

What do IMPs look like when installed?

They look just like other quality metal roofing and siding products, both on the interior and exterior. That is because the full range of standard metal products can be used with the foam core to create the IMPs. Hence, the diversity of striated profiles, architectural panels or textured panels are all choices for the final appearance. Similarly, all standard and custom colors available on metal roofing and siding are also available on IMPs.

How economical are IMPs to use?

There are several space, time and cost saving features of IMPs that make them very economical compared to other types of construction systems. Because of the insulating capabilities of IMPs, less insulation space is needed to comply with building energy efficiency codes compared to fiberglass insulation. IMPs are strong enough to allow for fewer structural supports than single skin panels due to greater spanning and load bearing capabilities, providing an economical and efficient building envelope. IMPs allow for fast erection times and easy installation, resulting in reduced labor costs and earlier business starts. Once installed, metal roof and wall systems require minimal maintenance and can lead to potential cost savings over their lifetime, including lower energy costs, maintenance costs and replacement costs.

What are other benefits of using IMPs?

In addition to all of the advantages already stated, using IMPs for building projects yield many benefits. This is true not only for the building owner, but also for the building designer and erector. For more complete information on benefits from these different perspectives, see our prior blog post on this subject.

To learn more about insulated metal panels for wall and roofing applications in general or to investigate if they are right for a project you are working on, contact your local Ceco representative.

The components of a metal building are known for their durability and longevity, but like any building material, improper handling can lead to problems. This is especially true in winter months when metal building components can be exposed to unusually harsh conditions.

Manufacturers routinely provide most or all of their metal building components with a protective shop coat covering all sides and surfaces of the metal. However, this shop coat is only intended as a temporary coating designed to protect the steel during shipping and building erection. As such, it typically performs when guarding against normal atmospheric conditions until a finish coat can be applied as the building is completed. However, these shop coats are never intended or warranted to protect against unusual or harsh conditions that may be encountered throughout winter months. For that, other measures are needed.

The Problem: Roadway Chemicals

Metal buildings are shipped by flatbed truck over highways and byways to the intended location. During winter, those roads are often treated with salt or chemical deicers to make them safe for travel. These chemicals don’t stay on the road, though, as anyone can attest who has driven on them and headed to a nearby car wash soon after. The concern is not just appearance, but the corrosive nature of the chemicals on the metal parts of a car or truck. The same is true for metal building components that are shipped on an open flatbed truck – deicing chemicals and salts can end up coating the metal, penetrating the shop coat, and causing corrosive damage.

The Solution: Protective Tarping

The easiest and least costly way to avoid corrosion and rust damage to metal building components during shipping is to request that they be protected with a tarp over the trucked shipment. Most manufacturers use third-party shippers who will readily provide effective tarping for a modest charge, making it a very inexpensive safeguard. For anyone choosing to pick up materials with their own trucks, it is important that the tarp is made of appropriate weatherproof material, that any D-rings or grommets are sound, and that the tarp is tightly and securely fastened without the possibility of holes developing during transit. Such holes could allow water, snow, or ice to penetrate and pool on the metal components, causing damage from freeze-thaw conditions or by carrying corrosive chemicals along with it.

Onsite Protection

Once metal building shipments arrive at the jobsite, the concern for protection continues, especially in winter. Ideally, the steel can remain on the bed of the truck and be directly offloaded into place as part of the erection process. However, if any of the metal parts are being offloaded and need to be stored on the ground, then they should rest on something to protect the metal from ground moisture or other conditions. A ground tarp could achieve that; so could a finished concrete slab. In addition, the metal should be covered over the top to help assure that any precipitation or moisture doesn’t have a chance to build up on the metal and compromise the primer or the metal. Of course, the storage location needs to be high enough that water flowing on the site doesn’t penetrate under the covering and pool around or on the metal.

All metal building manufacturers are well versed in the ways that do and don’t work to protect metal and the primers applied to them – they have probably seen it all. Therefore, to find out more about the best practices and ways to protect your next metal building project, especially in winter, get some more insights by contacting your local Ceco representative.

In our last blog post, we clarified the different ways to show compliance with energy codes—namely, prescriptive envelope trade-offs with COMcheck, or full computer modeling. For purposes of this post, let’s assume that we are going to use the envelope trade-off method to create an energy-compliant metal building while seeking to control construction costs.

Here are the steps to follow:

1. Determine Governing Code: Different jurisdictions (cities, counties, states) typically adopt different versions of national codes, such as the International Energy Conservation Code (IECC) or ASHRAE 90.1. Check with the local authority to determine which code(s) and which publication year(s) apply to your building. You can also see a listing on websites like www.energycodes.gov or http://bcapcodes.org/code-status/state/. Note that many places will allow the choice of an adopted version of the IECC OR ASHRAE 90.1 to show compliance; however, they cannot be interchanged. Only one or the other can be selected for the entire building to show compliance.

2. Determine Climate Zone: Both the IECC and ASHRAE 90.1 use the same definition of eight basic climate zones (listed by counties across the United States) to define prescriptive building requirements for components such as insulation. Hence, you need to identify the climate zone corresponding to your building location in order to find the proper information in the rest of the energy code.

3. Identify Prescriptive Envelope Requirements: Look up the prescribed requirements for walls, roofs, and floors specifically for metal buildings in the selected energy code based on the appropriate climate zone. This will provide a starting point for determining how easy or challenging it might be to achieve those levels for your building.

4. Make Construction Method Choices: Consider other alternatives in construction methodology. For example, would standard batt insulation in the walls be easier to install than adding what the code refers to as continuous insulation (ci)? This requirement for ci is usually met with rigid foam insulation installed outside of the metal structural components and under metal roofing or siding. Consider a few scenarios that make sense from a construction and cost-efficiency standpoint.

5. Run COMcheck: Take each identified construction scenario and put the relevant information into COMcheck, the free computer software commonly used to show energy code compliance. It is simpleto use once basic wall, roof, window, door, and floor areas are identified, along with the corresponding R-values or U-factors for each. Once the first one is completed, it can be saved and a copy made to compare it with a different scenario of insulation levels or other details. Going forward in this way, multiple options can be assessed pretty quickly and easily to see which ones meet or exceed code—and which ones don’t.

6. Compare Costs: Once the different options are identified that meet the energy code, you can compare the known material and labor costs of the different options to determine which makes the most sense. See the example below.

Example Metal Building Project:
Size: 60x100x20 with 1-1/2:12 pitched roof
Climate Zone: 2

Scenario 1 (based on prescriptive code requirements):
Roof: R-30 Liner System
Walls: R-13 faced insulation PLUS R-6.5 continuous insulation
In this scenario, the roofing liner system is fairly straightforward to install, but the requirement for continuous insulation in the wall requires more material and labor cost.
Total estimated insulation cost: $16,902

Scenario 2 (proposed design alternative run in COMcheck)
Roof: R-36 Liner System
Walls: R-19 faced insulation
In this scenario, the amount of insulation in the roof is increased and the wall insulation is consolidated into one installation.
Total estimated insulation cost: $10,045

Result: Both scenarios are shown to be compliant with the energy code, but scenario 2 reduces the installed insulation cost by $6,857, or 40 percent. (Note that this is an example only for the specific conditions noted. Actual results will vary, of course, with different buildings, different materials, and different locations.)

To learn more about different ways to insulate metal buildings effectively, see http://www.mbma.com or https://www.cecobuildings.com.

Content for this article was provided by Kyle Smige, District Manager at Therm-All. Therm-All is a pre-engineered metal building insulation laminator that provides an assortment of product lines and accessories, exceptional customer service, and energy code compliance consultation.

Thermal insulation is used in metal buildings to reduce heat flow between the inside and outside of walls and roofs, thus helping to keep the building warmer during heating season and cooler during air conditioning season. For building owners, that means lower energy use and the resulting lower cost of purchasing energy. The question often becomes: How much insulation to use—and where? Energy codes give us a starting point by identifying minimum acceptable levels of insulation in buildings.

The International Energy Conservation Code (IECC) is the primary energy code used around the country, although different versions exist since it is updated every three years. This code—and many jurisdictions—also recognizes ASHRAE 90.1 as an equivalent (not identical) energy performance standard that is acceptable to show energy code compliance for commercial buildings. Both of these documents include choices in how energy performance can be accomplished by offering three fundamental but different compliance paths:

Prescriptive:

This compliance method literally prescribes specific requirements for insulation, doors, windows, etc. If a building is designed and constructed in accordance using the prescriptive values found in tables and text in the IECC or ASHRAE 90.1, then it meets code in the most direct manner. Note that under the prescriptive method, R-values of insulation are prescribed based on assumptions made about the rest of the wall or roof construction. A prescriptive alternative is allowed that uses the U-Factor of the total wall or roof assembly to be calculated, but these are more conservative and usually end up requiring slightly higher R-values for the insulation to show compliance.

Envelope Performance Trade-Off:

The code recognizes that there is more than one way to meet energy efficiency goals, so it allows building designers the flexibility to create differing wall, roof, and floor conditions, provided the total building energy performance can be shown to match the total prescriptive level of performance. That means that trade-offs can be made between, say, the roof and wall insulation, where one might be less than the prescriptive code level but the other is more, so the trade-off balances out overall. The method used over 90 percent of the time to determine if trade-offs are code compliant is to use the U.S. Department of Energy’s COMcheck software, available for free download at https://www.energycodes.gov/comcheck. By entering some basic information about wall area, roof area, windows, insulation levels, etc., the software does the calculation and determines what percentage the proposed design is better than, or worse than, the prescriptive code level.

Computer Model:

Both the IECC and ASHRAE 90.1 allow for a full-blown computer simulation to be performed on a building to show overall code compliance. Under this approach, all building systems that affect energy use, including building envelope, HVAC, electrical, and process water equipment, need to be modeled with trade-offs acceptable between all. The computer simulation of the proposed design must be shown to perform better than an equal design that is based on the prescriptive code requirements as a baseline comparison. This method is usually reserved for larger, complex buildings or those where special conditions require it, such as large glass areas or non-typical construction.

Understanding these basic choices in energy code compliance is the first step in pursuing alternative ways to meeting energy requirements while staying within a construction budget. In many cases, particularly with metal buildings, simply striving to meet the prescriptive levels of insulation, for example, can imply additional costly construction either because of impacts on the building materials, additional labor costs, or both.

In our next blog post we will review additional steps for determining a code-compliant, cost-effective metal building design. In the meantime, you can learn more at http://www.mbma.com or https://www.cecobuildings.com.

Content for this article was provided by Kyle Smigel, District Manager at Therm-All. Therm-All is a pre-engineered metal building insulation laminator that provides an assortment of product lines and accessories, exceptional customer service, and energy code compliance consultation.

Have you ever wondered why there is an increasing push for insulated metal panels, or sandwich panels, in the industry, and how you can benefit from using it in the design and fabrication of your building? The Metal Construction Association (MCA) defines insulated metal panels (IMPs) as “lightweight composite exterior wall and roof panels with metal skins and an insulating foam core.” Their superior insulating properties, increased spanning capabilities and single-step installation make them efficient and cost-effective, particularly when compared to other wall assemblies. And IMPs are available in an assortment of colors, widths, profiles and finishes, allowing for a wide variety of aesthetic appearances for walls and roofs. Let’s look at some of the specifics behind these benefits.

Benefits to Design Professionals:

Design Flexibility: Insulated metal panels are available in a variety of flat and corrugated surfaces suitable for exterior walls, interior walls and roofs. IMPs are strong enough to allow for fewer structural supports than single-skin panels due to greater spanning and load-bearing capabilities, making them easier to integrate into building designs. They come in multiple profiles that can be used in either horizontal or vertical designs, including the availability of custom modular widths and factory-formed corners. Rounding things out is the full range of colors, reveals, and detail accessories that can support or enhance any design. They are also available with applied finishes to create a stucco, wood and other aesthetics.

Environmentally Friendly: It is common for a significant portion of the steel used in IMPs to come from recycled materials. Further, the insulating properties of IMPs with significant R-values can meet or exceed current energy codes and contribute toward credits in the Leadership in Energy and Environmental Design (LEED) Green Building Rating System. Because of the higher R-value insulation used in IMPs, less insulation space is needed in wall assemblies compared to other wall systems.

Fire-Resistant Solutions: In cases where one-, two- or three-hour fire-resistance ratings need to be part of the design, composite IMPs are available, using non-structural mineral wool insulation fabricated and tested to achieve the needed fire ratings.

Benefits to Construction Trades:

Ease of Installation: Since the interior and exterior faces of insulated metal panels can act as the finished surface, and the panel provides the required thermal, air, vapor and weather barrier for an exterior wall, they take the place of many separate products. This means there are fewer vendors and trades to manage during construction, streamlining the process and saving on costs. And IMPs are unaffected by most weather conditions, which allows flexibility in meeting construction time schedules.

Quick Construction Time: Most insulated metal panels are attached with a concealed fastener system in the side joint that streamlines their installation. This allows them to be quickly installed in a single step, significantly reducing construction time and getting “closed in” sooner.

Benefits to Building Owners:

Cost Effectiveness: The design flexibility and construction benefits noted above allow owners to capitalize on reduced first costs of the building. In addition, the energy efficiency, long term durability, and ease of maintenance typical of IMPs can save on operation costs as described below.

Energy Efficiency: The higher R-values possible with insulated metal panels means better control of heat flowing into or out of the building. Better heat flow control means better control of the energy, and associated costs, used to heat and cool the building.

Strength and Durability: The strength of the metal, including the presence or absence of corrugations, combined with the proven structural capabilities of the foam core, determine the overall strength of IMPs. This composite structural system provides their initial strength plus the ability to be durable enough to resist impacts and other forces during operation.

Longevity: Metal buildings using IMPs have been shown to last quite well as evidenced by decades of use. In most cases, the quality and strength of the steel can be selected to resist the conditions at the building. Similarly, the type of finish can be selected to withstand weather and operating conditions. Depending on local environmental conditions, their projected life could span 50 to 60 years and beyond.

Low Maintenance: Because of the inherent strength, durability, and longevity of IMPs, they typically require minimal maintenance. That means they can help owners save on annual operating budgets as well as long-term capital replacement projects.

With their simplicity of concept, design flexibility, efficient construction, and long-term performance, it is easy to see why insulated metal panels carry benefits for everyone involved. Visit our products or contact a rep to learn more.