Yes Virginia, you can always build it cheaper. And it will always cost you more..

My apologies for the literary reference to the old Santa Claus story from the young girl who wrote the New York newspaper "The Sun" back in 1897 - and I'm sure you know the story so I won't go into it here.  And I also have young children who ask me if there is a Santa Claus.  And as a company we field questions every day from people who ask why would they build their home out of our panels - because they can build it cheaper out of stick (like 2x4 or 2x6 lumber).  And this is after we have already tried to educate them on the benefits of our product.  Yes, yes you can build it cheaper out of stick.  And you could also put up a tent and make it even cheaper.  And you could ride a bike everyday to work, too, because a bicycle costs less than a car and you would save on gas.  Oh, you live 20 miles from home and that would be too much?  OK, then drive your car.  But you could purchase - for a little bit more - a fuel efficient car.  Actually if you take this grand analogy one step further, THAT is why you would build your home out of our very unique polyurethane core structural insulated panels.  They will provide a stronger, safer and SIGNIFICANTLY more energy efficient home than you could ever get out of traditional stick construction.  And - here's the rub - it can actually cost you less than stick construction.

How's that? Because we have seen time and again that while a client may pay a premium for our product over stick construction (and sometimes we cost about the same as stick construction - see our testimonials) - the energy savings in the VERY FIRST MONTH can be greater than the incremental cost of financing our product along with the rest of their home in a standard mortgage.  Let me say that another way - when you combine your home mortgage payment with your energy bills, a stick-built home can cost you more EVERY MONTH than that same home made from our panels.  And this does not even begin to account for reduced home insurance premiums or reduced maintainance costs.  Yes, your mortgage amount may be less if purchasing a stick-built home, but your energy bills can be 70% more - far erasing any savings on a cheaper mortgage!!!  And this doesn't even begin to include the increased home comfort or the quieter, safer and healthier living environment that building with our panels can offer.  And it also doesn't consider that while you can lock in a rate with a mortgage, your home energy costs will go up an average of 2.5% a year - every year (this according to US Dept of Energy).

There are not many investments out there that can offer a positive return on investment in the VERY FIRST MONTH.  But we have heard it from our clients time and again.

Yes, you can add up all your numbers and you can probably frame that stick-built wall and throw some spray foam or fiberglass insulation in there for less than the cost of our sips panels.  Congratulations!  But this is not a fair cost comparison, and you are really missing the point, as I have tried to explain above and on our website.

Whether building with 2x4 or 2x6, standard stick construction is the WEAKEST and LEAST ENERGY EFFICIENT method of construction allowable by law - and this is how most people or builders want to build their homes?  With no remarks about Santa Claus (in case my girls read this!) it is sheer fantasy to believe that building it cheaply will mean that you'll get the best home, and yet that is what this country chooses to do time and time again.  Actually I believe that eliminating stick construction is the single greatest "opportunity" for reducing CO2 emissions and other greenhouse gases that our country has - and the US Dept of Energy has essentially said the same thing.  Just run the numbers - homes and commercial buildings are one of the single greatest users of energy in North America, and the heating and cooling of those structures is most often their single greatest expense.  And that is where we come in.

Ice Storms and High Winds

It is a rather early and rough start to winter eather for most of the United States and Europe.  Wide spread ice storms, record-braking extreme temperatures, large snowfalls and 90+ mile per hour winds are unseasonable in the late fall, though extreme weather events like these - all seen in only the past week - appear to be the new "normal" in our world.  (And didn't we just come from a summer of record breaking HOT weather?)  And with all of these events, how our homes are constructed can mean the difference between comfort and truly hard times - or worse.  Where we live in western North Carolina we have seen power outages lasting for many days at a time, mostly due to ice storms or similar.  And when you lose power, your home can become very cold - or very hot, very fast.

A stick-built home, as we have discussed before, has a wooden frame that is about 25% of the surface area of the building envelope (this according to USDOE building scientists).  Since wood has an R value of one per inch (R1), this means that 25% of your home is about R4 in insulation.  Windows and doors, also comprising 20-25% of your home's building envelope, also have an R value of around R3 or R4.  That means that close to FIFTY PERCENT of most stick-built homes have an R value of about R4.  It starts to not even matter how you insulate the rest of the home if you are starting with 50% at R4 - it all comes down to weighted averages of surface area.

The Eco-Panels system is the only structural insulated panel system on the market today that can offer a CONTINUOUS envelope of insulation around your home, uninhibited by framing members at the panel joints or corners as other systems have.  And when you have a super insulated building envelope, things like solar orientation start to matter less (think about it) because the effective efficiency of any heating or cooling device you have starts to increase dramatically.  We know of one of our buildings presently seeing sub-zero temperatures that is being comfortably heated with a small portable electric heater that costs about $30.  AND the building is still moderately warm the next day when the occupants return for another day of business.

Stronger - safer - and significantly more energy efficient than stick-construction.  Eco-Panels - for an increasingly chaotic world.

Most Energy Efficient Home in America?

Most all stick-built homes today have an R-value of approx 4 or 5 for around 50% of the building envelope!  This is because the "framing factor" - or the amount of wood framing cutting through the walls & roof and floor of the house amounts to about 25% of the structure (based on ORNL study), and since we like to have windows & doors & garages there goes another 20-25%.  All of these items have very low R values, often ranging from R3 to R5 - so at some point it almost hardly matters whether you have spray foam or fiberglass insulation between the studs - you are already fighting a losing battle.  And that is where Eco-Panels comes in!

A home we recently (late 2012) provided wall panels for in the mountains of western North Carolina - not far from the Tennesse border - was able to achieve a blower door test rating of 0.282 ach50!  Now for those who do not know, this means quite simply that the home is very well sealed and "energy tight".  The average new home in America may have a blower door rating of around 7, and Energy Star version 3 homes in North Carolina have to rate at 4 or 5 ACH50 (depending on climate).  This home we provided panels for is almost 25 times better sealed!!!  Based on interviews with building science professionals as well as extensive web searching, right now we believe that this is the "tightest" home in the United States.  Of course any (good) expert will tell you that a super-tight home by itself will not necessarily qualify you for very low energy bills (think of a well sealed glass cube - it is not at all well insulated).  But when you combine a super-insulated building envelope (R26 walls and R40 roof) with super-tight construction you are virtually guaranteed low energy bills (for heating & cooling, the single primary energy use for buildings in the US).  You don't need a whole Passive House program with double stud walls to get a super energy efficient home!  (double stud walls actually take quite a bit from the floor square footage and of course require more labor & materials).  In most climates you actually don't even need very high R values WHEN USING OUR PANELS.  Some programs require an R60 roof - but this assumes that it is built in a more traditional manner and it assumes that there will be lots of thermal bridging.  Listen, we've shipped R60+ panels before, but most of them have gone to regions near the arctic circle.  If you investigate what some people call "the R value fairy tale" you'll learn that when working with superior insulating materials like our closed cell polyurethane foam, the first several inches will do the lion's share of the work.  You simply do not need the same thickness of product as antiquated systems require, and you enter a discussion of "diminishing returns" when you start piling on extra inches of foam.

This particular homeowner's first real energy bill - though it was only for 24 days - was less than $35 and his home is several thousand square feet in size.  This amount would include things entirely unrelated to heating & cooling - heck most people can spend $1/day just on water heating, plus you need lighting, your refrigerator, TV set, etc.).  This could easily be a net zero home if the owner had wanted to fill his roof with PV panels (it does have 1kW of panel), but I know he is too practical for that (actually the whole definition of what qualifies to be a "net zero" home is quite flaky, but that's another conversation).

Brian Knight of Springtime Homes in Asheville, NC, was the builder, and here is a blog article discussing this build.

We had a builder tell us last week that we were about $3-4k more than the competition - on a $300k home.  And he walked.  THIS IS WHY you pay a little bit more.  Eco-Panels is simply a better system.  The sad thing is most people will spend more money on their kitchen cabinets & countertops than they will on our panels.  The homeowner whose builder walked would probably have earned a positive return on that small premium in just a couple of years and then he'd be MAKING MONEY from then on compared to a stick-built home!  We will GUARANTEE that there is no air leakage at our corners when using our single piece corner panels - impossible for others to entirely insulate or air seal perfectly on a consistent basis.  My advice - think twice before you bid your home to the low bidder - and don't let them install cheap materials to build your home.  So many say "I've been building homes this way for 30 years - and my daddy built them before me - and if it was good enough for his clients it's good enough for mine!"  If you are the homeowner that will be owning the home, find a good builder that will build with the best products - not the way they built 50 years ago.

Here are several pictures of the home, both under construction and finished.  Note that our wall panels used Huber ZIP System as the exterior siding.

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$47 Energy Bill in South Carolina in the Summer!

Earlier this year Eco-Panels had the pleasure of working with Donald "Don" Cerra of Cerra Homes out of Aiken, South Carolina, part of the up-state region bordering on northern Georgia.  Don impressed us with his committment to "green" yet sensible home construction.  We recently had a chance to have a follow-up conversation with Don about his and his subcontractor's experiences working with Eco-Panels and our unique polyurethane core SIPs, the most advanced panelized building system on the market on truck.jpg

"The home is being build to the DOE Challenge Home program.  DOE Challenge Homes are verified by a qualified third-party and are at least 40%-50% more energy efficient than a typical new home. Matt Ryan with ELM Energy Group out of Charlotte,NC handles all the enrollment testing and part of the paper work. I'm required to do some of the in the field paper work during the build process. I use a from of LEED (leadership in energy and environmental design) integrated design concept to start the green build process. Simply stated I work with all my suppliers and parter vender to select the best dollar value for every component of the house. This helps me stay with-in my clients budget and get them the best house they can afford.  

With all that said the current project using ICF foundation for a conditioned crawlspace and 4.5" R26 rated Eco-Panels for the exterior walls and 2+ inched for closed cell (never open cell) spray foam over the ceiling and 10+" of TAP cellulose blown in over the foam giving the attic ceiling R-50 has a project annual operating cost of $600.00 per year. Just as an example Junes cooling and construction load with no insulation in the attic for the first 15 days was $47.00. This house is 2500 sq ft conditioned!  first panels going up.jpg

This was the first house in Aiken to use Eco-Panels and the support from the office to the onsite assembly was outstanding. My framing crew was very please with how fast and easy the panels went up. My electrician was amazed how well we had laid out the exterior wall electric boxes and conduit to the crawlspace. The drywaller was also pleased with the ease of installing the drywall to the Eco-Panels. 

You know I always get asked what make it green and there is no real one or two sentence answer. I will say this its is analmost finished home - aiken sc.jpg attitude more then anything else. If you are laze fair about the process you may build a house that is energy efficient on one have but not health and comfortable on the other. You may use sustainable materials but then order more then you need and trash them because most often these materials are special order. I try very hard to control material cost, just ask my framer. He has a cutoff pile that he picks from daily and no dumpster on site until the roof is sheathed. This avoids the temptation to just throw that 18" piece of 2x4 away. I'll find a use for it!  

The construction site is also has many possibilities for recycling  such as paper, plastic, aluminum cans, and cardboard. Hence the picture of the back of my SUV. don cerras recycling mini-van.jpgI made no less then 12 trips to the drop off station. All my crews know it is required of them and they do a good job of follow through. It is hard sometime though because they are not required on most other job site so they forget from time to time. An attitude of cooperation exists with each trade trying to set the stage for the next crew to preform it task unhindered. It's not perfect but if I don't try then I'm just another builder turning out an average home. I remember my dad telling a client one time that he was not going to get any better house then the one we were building across the street. My dad said every client gets the same professional job and quality the only difference are the materials. I'm not sure the guy liked the answer but that’s who and what I believe. The best I can do no matter the cost to Cerra Homes LLC.

Nice meeting with a fire captain

All the time we host interested potential clients to visit our factory and yesterday we had the honor of hosting a fire department captain - who also works as a builder on his off-shift days - looking to build a couple of buildings himself - from a garage/workshop to a home for a relative.  Being an inquisitive person myself I never miss the chance to learn when possible and fire safety is of particular interest to me, and to meet with a fireman who was also a builder was particularly great conversation.

Similar to the videos on our website homepage (scroll down if you did not see them!) we played around with "burning foam", and marveled that most EPS panel manufacturers are able to claim a "Class 1" fire resistant material because this test (ASTM E84) actually only tests for flame spread and smoke spread - and when their material simply either "vaporizes" or melts when flame is in contact with foam, there is almost no smoke or flame.  The problem is - as we both observed - if you remove the interior of an EPS panel through heat then YOU LOSE STRUCTURAL SUPPORT.  i.e. the HOUSE COLLAPSES.  And the challenge for fire fighters is that they do not know what a home or building is made from - and they may rush inside or climb on the roof to fight that fire because that is simply what they do.  And if the structure is made from EPS panels and not sufficiently protected from flame - they could be severly injured or worse.  The heat at the ceiling inside even a simple kitchen fire can reach 1700 degrees, and EPS foam starts to melt at around 200 degrees F or less.  For this reason in the UK the insurance industry largely will not insure new structures built with EPS panels (though it is still legal by building code).  Even the "open vented" nature of most test facilities testing the structural support of an EPS panel in fire to not reflect real world enclosed house situations in which heat builds up inside of a structure.

We also discussed tornadoes and hurricanes - shear wind events for which North Carolina is known to see often.  The senior building code official for Wake County once told me that our product really helps the latest building codes because asided from increased insulation values the Code has increased it's "Bracing" section of the code from around 6-8 pages to more than 20 pages - three times as much.  And when we manufacture a single piece corner panel - eliminating one of the weakest parts of a home's structure - where two walls come together - we can significantly increase the overall structural strength of a building when coupled with our wall panels that amount to shear walls by themselves (through inherent cross-bracing in every panel we build).

Eco-Panels can make your home stronger, safer and significantly more energy efficent.  Please consider us for your next home!


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