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Affordable Panelized Wall System

Affordable Panelized Wall System

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Affordable Panelized Wall System

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  1. Affordable Panelized Wall System Group 15 John Mitchell Chris McNeill Samantha Gonzales Heidi Sookram Department of Mechanical Engineering FAMU- FSU College of Engineering

  2. Outline • Introduction • Design Selection • Product Specifications • Design Explanation • Panel Manufacturing • Testing and Analysis • Cost Analysis • Future Considerations • Acknowledgements

  3. Introduction • Design a wall panel to lower the cost of home ownership over a 60 year period. • Exterior walls of a home for affordable housing • Utilize volunteer’s • Must be small enough to not require heavy lifting equipment • LEED Compliant

  4. Types of Panel Systems Metal Frame Wall Panel Pre-Formed Concrete Wall Panel Wood Frame Open Wall Panel Wood SIP Wall Panel Images source: www.huduser.org/Publications/PDF/path_panel_conntn_report.pdf

  5. Design Selection

  6. Product Specification

  7. What is a wood SIP? • 2 pieces of OSB sandwiching a block of insulating foam • Devise a method to connect panel at all points • Panel to panel • Panel to floor and roof • Corner connections **Include pro/e drawings of each connection type

  8. Manufacturing

  9. Panel Manufacturing • Adhesive chemical reaction pushes OSB away from foam • Need to find a method to offset the reaction OSB EPS Foam

  10. Panel Manufacturing Pump pulls air out to compress panel at 15 psi for 2 hours Vacuum bag preparation Roll adhesive over both sides of foam Panel ready for compression

  11. Panel Testing and Analysis

  12. Structural FE Analysis • Doubled design load requirement to 240 psf. • Maximum stress ~ 1300psf • Concentrated in corners

  13. Deflection Testing The total span is 7.5 ft. The panel deflected 3/8” under a load of 1440 lbs. • Simulated pressure load from high winds • 1 ¼” deflection under 112 psf load. The panel deflected 1.25” under a load of 3400 lbs

  14. Wind Load Analysis • Same static load • 86.5 psf load applied perpendicular to wall surface • Result was wall deflection • Maximum stress achieved is 15,600 psf

  15. Long Term Cost Analysis

  16. Cost Analysis • Our Goal • Lowest total cost of ownership over 60 years • Two main components of overall cost • 1) Initial construction cost • 2) Cost of operation over lifespan of home • Set up reference house for basis of comparison • Traditional wood framed house – 2”x4” stud construction

  17. Material Cost • Wood Frame • Sill plate • Dimensional lumber • Studs • Plywood siding • Fiberglass batt insulation, R-13 • Gypsum wallboard • Vinyl siding • Wood SIP • Sill plate • Dimensional lumber • Structural grade OSB • EPS foam core • Adhesive • Gypsum wallboard • Vinyl siding

  18. Annual Energy Cost • EnergyGauge USA home energy simulation software • Model home • 1120 ft2 floor area • Concrete slab foundation • 76 ft2 window area – double pane windows • R30 insulated roof • Appliances • Different Exterior Walls • All other parameters constant

  19. Annual Energy Cost

  20. Long Term Energy Cost • Account for costs over 60 years • Annual energy costs transformed into Present Value using geometric series present worth factor: G = first year payment i = annual interest rate, 3%, e = annual escalation of electricity cost, 5% n = number of years

  21. Long Term Total Cost (ex. Minnesota)

  22. Concluding Remarks • Wood SIP is the simplest design • Panel Manufacturing is straight forward • Shows promising results under adverse weather conditions • Higher initial cost, Lower long term cost • Easy to implement into an affordable housing program

  23. Future Considerations • Confirm capacity for seismic resistance using full scale model • Perform structural analysis utilizing actuators for load application • Refine the manufacturing process • Use independent testing to certify panel for use in construction • Perform more detailed flood analysis

  24. Special Thanks • Jerry Horne at HPMI • Ron and Bob at SIPS Team USA • Dr. Abdullah, WHEEL Lab • Dr. Jung, Civil Engineering • Daniel Knapp, Dow Building Products • Dr. Ordonez, Faculty Advisor • Terry Shaw, Cummins, Project Advisor

  25. ???Questions???

  26. Flood Resistance Testing • Testing: • Adhesive bond • Connection leakage • Panel strength • Results: • Filled to 3.5 feet (218 psf) • No leaking through connection • No deflection • No signs of moisture inside panels

  27. Sample Calculations Found using the compressive strength of each material multiplied by its area fraction of the wall panel, then summed. Nominal stress in the wall panel under static design load of 120 psf