Comments on: Ply-on-foam walls increase energy efficiency

By: Murray Thaler

Murray Thaler — Thu, 20 Aug 2020 05:20:48 +0000

Salute to Ben, What a good example making the impossible to possible. It works as long as the plywood is totally sealed. Any moisture entering the plywood could cause it to warp. If the bond between plywood and sub-floor is strong, the wordage could include the sub-floor.

By: Sharing Resource Performance: The latest dMASS newsletter — dMASS

Sharing Resource Performance: The latest dMASS newsletter — dMASS — Fri, 18 Mar 2011 13:08:31 +0000

[…] Ply-on-foam walls are 40 percent more efficient and are stronger than traditionally-built walls. […]

By: Zero Net Energy Homes at Sage Green | Green Blog Media

Zero Net Energy Homes at Sage Green | Green Blog Media — Fri, 01 Oct 2010 10:49:44 +0000

[…] the use of a styrofoam and plywood wall assembly — something Ben Walsh of Green One calls ply-on-foam. In addition, efficient features include triple-glazed windows, CFL lighting, and high efficiency […]

By: Ben Walsh

Ben Walsh — Thu, 11 Mar 2010 17:23:08 +0000

Glenn,

You’re right that polyiso is about 20% more R per inch than EPS, but it’s also about 40% less R per dollar. Polyiso’s flame spread is only significantly better than EPS if it has a facing on it, which can reduce vapor permeability to almost zero, commonly called out at about 0.03 for polyiso, compared to 5.0 for unfaced EPS. OSB is about 1.0. Unfaced EPS has a flame spread rating of about 20, while common wood structural panels products (shear sheathings) are all in the 75-200 range. So, at least compared to conventional practice, it’s a significant improvement with regard to fire as well.

By: Brady Peeks

Brady Peeks — Thu, 11 Mar 2010 06:27:19 +0000

My hat’s off to Ben for not only working to get this alternative construction method approved for his own project, but for having the follow-through to get structural testing performed on the assembly. The improved seismic performance certainly is an unexpected and almost counter-intuitive finding. Thank you for this contribution that looks to be a hugely cost-effective improvement to the Oregon house of tomorrow. I hope the State can see its way clear to pick up on this idea and take the next steps in proving it out and making it easy for other local jurisdictions to allow its use.

By: jim russell

jim russell — Wed, 10 Mar 2010 16:37:08 +0000

Rarely to do you see people take on issues, even more rare during times of economic challenge. This is an exciting new development to conventional construction combining the efficiency of a foam composite wall with the added benefit of tremendous strength. Of interest to us is the shear resistance. Particularly exciting is the relatively minor cost impacts. Ben is doing something that is a significant contribution to energy efficiency and residential construction.

By: Glenn Coughenour

Glenn Coughenour — Wed, 10 Mar 2010 16:02:05 +0000

This is a reasonable idea except for the flammability of EPS foam. An alternative like polyiso foam has much better fire retaredant proerties and also much better insulation value.

By: Mike Fruzzetti

Mike Fruzzetti — Wed, 10 Mar 2010 15:21:53 +0000

Glad to see Ben advancing this concept…and having the guts to put it “into reality.” Many talk about doing things like buildng zero-net homes and promoting new technologies…Ben is one of the few doing it. The advantages of “the wall” present exciting possibilities in regions known for their “ground breaking” potentials. Imagine homes in Haiti rebuilt utilizing this new building advance. Way to go Ben!

By: Ben Walsh

Ben Walsh — Wed, 10 Mar 2010 00:41:08 +0000

91��Ƶ has corrected the inaccuracy of their original description. These aren’t SIPs. They’re conventional site-built, stick-framed walls with a layer of rigid foam board over the framing under the sheathing. There is only one layer of wood structural panel sheathing.

We’re certainly not the first to have conceived of such a “ply-on-foam” assembly. APA Technical Note C465E from August 2006, discusses T1-11 over 1″ of foam as an alternate to conventional IRC wall bracing with respect to shear. Apparently industry insiders in the Seattle area know this as “the Martha Wall”, after Martha Rose of Martha Rose Construction.

The substance of the patent claim(s) is delivering improvements in seismic capacity.

By: Nathalie Weinstein

Nathalie Weinstein — Tue, 09 Mar 2010 22:56:53 +0000

Gary, Mr. Walsh certainly isn't the first and I hope I did not imply that. We've run articles on builders using structurally insulated panels before, including an article on a house that used Premier Building Systems: http://djcoregon.com/news/2008/03/06/sips-make-northeast-portland-home-project-a-first/. But the fact that Walsh is seeking a patent for this method is unique, as are his efforts to get the technique recognized by the Oregon building code, and OSU's acknowledgment that the assembly has great seismic qualities. I'll be sure and keep Panel Source Inc. in mind for future articles. Thanks for reading!