Andy Turner from Nuform Building Technologies presented on building envelopes and thermal mass walls. [1] Nuform was founded in 1992 and provides building systems and technologies. [2] The presentation covered the benefits of envelope construction including speed of construction, limited site disturbance, and energy efficiency. [3] It also discussed moisture management, wall physical performance characteristics like R-values and sustainability, and the various types of concrete wall panels and insulation options.

1. Building Envelopes
and Thermal Mass Walls
Presented by:
Andy Turner
VP Sales and Marketing
Nuform Building Technologies Inc
Leed AP

2. History of Nuform
Building Technologies
Founded in 1992
 Royal Building Systems Technologies, LTD
Provides the world with leading edge
building systems and technologies
2007-Royal Building SystemsTechnologies
became Nuform Building Technologies
New Names-Same Great Products

3. Introduction
 Design, Engineering and
Specification Assistance
 Constructability Assistance
 Budgeting Assistance
 Sample Assistance
 Systems Testing
 LEED Analysis
 Thermal Analyses
 Construction
Comparisons

4. Introduction
Construction Comparison
 Site Cast
 Precast
 Conventional
 Poured In Place
 Metal Panel
 Conform

5. AIA / CES Program Purpose
 This program is registered with the
AIA/CES for continuing professional
education.
 As such, it does not include content
deemed or construed to be an
approval or endorsement by the AIA of
any material of construction or any
method or manner of handling, using,
distributing, or dealing in any material
or product.
 Questions related to specific materials,
methods, and services will be
addressed at the conclusion of this
presentation.

6. Learning Objectives
 Participants will be able to:
 Utilize the architectural aspects of
Concrete Wall Panels
 Understand how to insulate a
concrete wall
 Understand the benefits of a high
mass wall
 Understand the benefits of insulated
concrete walls in relation to energy
efficiency
 Understand overall panel thermal,
fire resistance, and moisture ,mold
and pest prevention properties
 Leed

7. Program Agenda
 Introduction to Envelopes
 Benefits of Envelope Construction
Speed of Construction

Limited Site Disturbance

Energy Efficiency
 Moisture Management
 Wall Physical Performance

R-Values

Sustainability

Durability

8. Introduction
Owner Benefits
 Benefits to Owners:
 Speed of Construction
 Limited Site Disturbance
 Attractive Appearance
 Energy Efficiency (R-30+)
 Increased Daylighting
 Long Clear Spans
 150 MPH + Low Maintenance
 Sound Transmission (STC 58)
 Moisture Management
 Fire Endurance (4-HR)

9. Comparative Construction Cycle Analysis
Inlaid Brick Architectural Concrete Wall=
Hand-laid Brick/Block Cavity Wall
Facility
Architect
Facility
CM/Contractor
Concrete Wall
Load Bearing
Panels with
Insulation,
Conduit & Brick
Architect
CM/Contractor
CMU Block
Scaffolding
Up & Down
Conduit
Grout & Rebar
Roof
Roof
Damproofing
Insulation
Brick
Scaffolding
Up & Down
Cleanup

10. Introduction
Limited Site Disturbance - Panelization
 Panelization:
 Modular Size
 Repetition

11. Introduction
Limited Site Disturbance - Panelization

12. Introduction
Limited Site Disturbance – Panelization

13. Introduction
Texture Options – Color, Form, and Texture
TEXTURE
Multiple Textures
Add Interest
Multiple Textures Add
A very economical way to enrich
Interest
the appearance of your school’s
A very economical way to enrich its appearance
precast exterior is to vary the
of the facility’s exterior is to vary its texture.
texture.
 Thin Brick and Stone
 Sandblasting
Concrete Sprayed Siding and Hard Plank
Steel
 Acid Etching
PVC
 Retarding (Exposed Aggregate)

14. Introduction
Retail

15. Introduction
Retail
Nordstrom
Irvine, CA

16. Introduction
Retail

17. Introduction
Retail

18. Introduction
Corporate & Office

19. Introduction
Hospitality

20. Introduction
Spiritual

21. Introduction
Education

22. Introduction
Military

23. Introduction
Military

24. Introduction
Barrier Walls

25. Introduction
Housing
 Residential:
 Dormitories
 Hotels
 Health Care
 Multi-Residence
 Single-Family
Energy
Efficient
Homes

26. Introduction
Housing

27. Introduction
Controlled Environments

28. Controlled Environments

29. Introduction
Health Care

30. Introduction
Health Care
Cook County Hospital
Chicago, IL

31. Introduction
Educational – Interior Walls
Walls are finished…..

32. Introduction
Educational – Interior Walls

33. Introduction
Educational – Interior Walls
 Minimal maintenance for
20 years or longer . . .
• Interior exposed concrete
surface needs only periodic
repainting
• Exterior wall surface totally
maintenance free, except for
caulking every 20 years +/
• If thin brick is used, no need
to tuck point concrete mortar
joints

34. Types of Concrete Wall Panels
Solid Concrete Wall Panels
=
 Question:
 Did you know that 7” of load-
bearing structural concrete
has approximately the same
R-Value as a single panel of
glass…R-1.4 !
 Insulation IS Important !

35. Types of Concrete Wall Panels
Insulating Options?
 Insulation Position is critical:
 Interior: Insulation separates you
from the mass effect
 Exterior: Outside of the bulk mass
of the wall system.

36. Effective R-Value
Thermal Efficiency in a Wall Panel
The ability of concrete to store energy and dampen the effect of temperature
change on heating and cooling systems is know as the “Thermal Mass Effect.”
Due to the mass effect of insulated precast walls, the performance R-value of the
high performance wall system can be two to three times greater than that of the
material R-value, resulting in energy cost savings up to or exceeding 50%.
High Mass Building
Conventional Insulated Building

37. ASHRAE 90.1-1989
Building Envelope
Performance Study
ASHRAE 90.1-1989
Performance Analysis
APPROVED
Calculations will show how
what R-Value a Integrally
Insulated High Mass Wall
Panel will perform at.

38. Construction

39. Non-Composite Sandwich Wall Panels
Connection Devices
 Pin Connector:
 Polypropylene
 Nylon
 No Thermal Transfer
 Molded Plastics
 No Quality Control
Pullout Capacity = 1100 lbs.
Shear Strength = 380 lbs.
Pullout Capacity = 1100 lbs.
Shear Strength = 500 lbs.

40. Sandwich Wall Panels
Connection Devices
 Insignificant Pull Out & Shear Capacity of Connectors

41. Composite Sandwich Wall Panels

42. Composite Sandwich Wall Panels
Thermally Inefficient Connection Devices

Thermographic image showing thermal bridging.

43. Conform Energy Efficient Wall Panels
Thermally Efficient

Thermo graphic image shows
thermal efficiency:

Edge to Edge Insulation

44. Integral Insulation
Expanded Polystyrene - EPS – “BEAD BOARD”
 ASTM C578 Standard Specification for Preformed Cellular
Polystyrene Thermal Insulation - EPS
Type
XI
I
VIII
II
IX
Density
min, pcf
0.7
0.9
1.15
1.35
1.8
R-Value/inch
@ 75 F
3.1
3.6
3.8
4.0
4.2
Compressive strength
min, psi
5
10
13
15
25
WVP, max
perm for 1”
5
5
3.5
3.5
2
Water Absorption
max., % by vol.
4
4
3
3
2

45. Integral Insulation
Polyisocyanurate – POLY ISO
 Polyisocyanurate:
 Closed Cell
 Variety of Facers.
 R-5.6 to R-6.5

46. Integral Insulation
Polyisocyanurate – POLY ISO
 ASTM C1289 Standard Specification for Faced Rigid Cellular
Polyisocyanurate Thermal Insulation Board
Type
Class
Facer
R-Value/inch
@ 75 F
Compressive strength
min, psi
WVP, max
perm for 1”
Water Absorption
max, % / vol
Isocast R
I
I
II
II
triplex aluminum
poly facer
Foil
Felt or Glass
Fiber Mat
6.5
6.5
5.6
25
25
16
<.03
<.03
1
0.05
0.05
1.50

47. Integral Insulation
Extruded Polystyrene – XPS
 Extruded Polystyrene:
 Closed cell structure.
 Integral high density skin and core.
 Typical R-values of R5.0 to R5.6 per inch.
 Magnified Cross Section

48. Insulation
 ASTM C578 Standard Specification for Preformed Cellular
Polystyrene Thermal Insulation - XPS
TYPE
X
IV
VI
VII
V
Density, min.,
pcf
1.35
1.60
1.80
2.20
3.00
R-Value/inch
@ 75 F
5.00
5.00
5.00
5.00
5.00
15
25
40
60
100
0.55
0.55
0.55
0.55
0.55
0.3
0.3
0.3
0.3
0.3
Compressive
Strength, min.,
psi
WVP, max.,
perm for 1.5”
Water
Absorption,
max., % by vol.

49. Moisture Migration

50. Insulated Concrete Sandwich Walls
Moisture Management
The problems associated with moisture and its affects on
building components are well known, and costly to repair.
Most Insurers have stopped coverage
for these incidents leaving owners
no other avenue for compensation
but the court system.
Bottom Line: No Moisture Means No Mold or Mildew

51. Insulated Concrete Sandwich Walls
Moisture Management
 In general, molds demand a favorable combination of
the following conditions to germinate, sporulate, and
grow:
 Fungal spores settling on the surface
 Oxygen availability
 Optimal temperatures between 40-70 degrees F
 Nutrient availability (wood, paper, cellulose based materials)
 Moisture (liquid or relative humidity above 70%)
 The first four conditions are met in almost every building.
 The key remaining factor is moisture, which may be controlled
by adhering to sound construction practices discussed in this
presentation.
Bottom Line: No Moisture Means
No Mold or Mildew

52. Insulated Concrete Sandwich Walls
Moisture Vapor Drive
Warm
Outside
Cold
Inside
In a Hot/Mixed Climate:
Diffusion from the exterior side of the
wall is also common.
In spring, summer, and fall, wind
driven rain can be absorbed in the
exterior concrete and stored.
Outside-In
Vapor Drive
Insulation is critical in preventing this
moisture vapor drive:
 Concrete can’t
 Exterior Paints can’t
After the rain, as the sun heats
up the concrete wythe, the
moisture turns to vapor and is
driven through the wall
Moisture will always diffuse,
especially if the perm rating is
greater than 1.0

53. Moisture Vapor Drive
Insulation will enhance the efficiency of
the entire wall system.
Cold Inside
Air
PVC Encompassed
Insulation and Concrete
form
Outside-In
Vapor Drive
Exfiltration

54. Insulated Concrete Sandwich Walls
Moisture Vapor Drive
 What Is Vapor Diffusion?
 The Process by which water vapor migrates through a wall
system and it’s components such as gypsum, concrete,
insulation and paint.
 Each components of the wall system has a perm rating
 The International Building Code says that a material with a
perm rating of 1.0 or less is a vapor retarder.
 Examples of the average perm rating for different wall
components…
 Gypsum
12 - 50 perms
 Plastic Sheet Barriers (2-10 mil)
.16 – .03 perms
 Rigid Insulation
5.8 – .03 perms
 Concrete
3.2 perms
 PVC
0 perms

55. Moisture Vapor Drive

Photograph showing thermal bridging
and moisture migration.

56. Moisture Vapor Drive
Removing wallpaper, mold and mildew
is prevalent throughout the entire wall.

57. Energy Efficiency
calate.
ncern.
 36% of ALL energy consumed in the
U.S. is consumed by buildings
 Natural gas prices are expected
to increase from 30% to 70%
compared to one year ago
 “Energy efficient building shell is
one that integrates and optimizes
insulation levels, glazing, shading,
thermal mass, air leakage control,
and light-colored exterior surfaces”
(Sustainable Building Industry Council - High
Performance School Buildings 2005 Second Edition)

58. Effective R-Value
Thermal Loss Through Wall Panel
 ASHRAE 90.1 recognizes thermal short circuits and
applies a correction factor to account for the higher
heat loss through highly conductive steel studs.
 Effective R-value = R-value x Correction Factor

59. Effective R-Value
What R-Value are you Purchasing?
Let’s look at the assembly of the Steel Stud / Brick Wall:
6” 20 GA S.S. @ 24” o.c., R-19 Batt + ½” Gyp.
Component
Int air film
Gypsum
Vapor retarder
R19 batt
Gypsum
Air space
Brick
Ext.air film
Wall Effective R-Value:
R-value
0.68
0.45
0.01
8.60
0.45
0.60
0.80
0.17
11.76
INTERIOR AIR FILM
GYPSUM BOARD
STEEL STUD
R-19 BATT INSULATION
EXTERIOR GYPSUM
AIR SPACE
MASONRY
EXTERIOR AIR FILM
The ASHRAE “PARALLEL PATH METHOD” was used to calculate the effective thermal performance for
the metal frame wall construction. The correction factors from ASHRAE Standard 90.1, 1989 User’s
Manual were used to assign reduced thermal resistance values for the insulated stud cavity.

60. Effective R-Value
Thermal Loss Through Wall Panels
 Solid Concrete Zones
 Metal Thermal Bridges
 Thermal Short Circuits

61. Effective R-Value
Thermal Loss Through Wall Panel

The thermal
conductivity of steel
& solid concrete
sections account for
significant thermal
losses!
Up to 60% thermal loss !!

62. Effective R-Value
Thermal Loss Through Wall Panel

Measurements of thermal loss in sandwich panels:
Panel Description
Material
R-Value1
Test
R-Value
Percent
Loss
Panel with
Only Steel Ties
Panel with Only Solid
Concrete
Panel with Solid Concrete &
Steel Ties
10.48
7.55
-27.96%
10.48
5.77
-44.94%
10.48
4.55
-56.58%
1.
Value obtained summing R-values for concrete & insulation layers, no air films included.
Note: All 3-2-3 panels made with extruded polystyrene.
Source: “Summary of Thermal Tests of Insulated Concrete Sandwich Walls U.S.Dept.
of Energy 1998-1999.” Composite Technologies Corp., IA, 1999.

63. Effective R-Value
Thermal Efficiency in a Wall Panel

Measurements of thermal loss in sandwich panels:
Panel Description
Material
R-Value1
Test
R-Value
Percent
Loss
Panel with only steel ties
10.48
7.55
27.96%
Panel with only solid
concrete
10.48
5.77
44.94%
Panel with solid concrete &
steel ties
10.48
4.55
56.58%
Conform Wall Panel
10.48
10.57
-0.86%
1. Value obtained summing R-values for concrete & insulation layers, no air films included.
Note: All 3-2-3 panels made with extruded polystyrene.
Source: “Summary of Thermal Tests of Insulated Concrete Sandwich Walls U.S.Dept.
of Energy 1998-1999.” Composite Technologies Corp., IA, 1999.

64. Effective R-Value
Thermal Loss Through Wall Panel

Thermographic image showing thermal bridging.

65. Thermal Efficiency
Energy Savings
This school is constructed with conventional
brick / masonry construction. It took 8½
months to construct.
This school is actually 4,000 sq.ft. larger but was
constructed with an integrally insulated sandwich wall
panel. Construction time was only 5½ months!
School Comparison
Electrical Cost
Natural Gas Cost
Traditional School
$118.89 per day
$100.78 per day
High Mass Wall
$91.02 per day
$65.95 per day
Percent Savings
31%
52%

66. Insulated Concrete Sandwich Walls
Sustainable Design – LEED
TM
United Nations Brundtland Commission Report (1987): Defined
sustainable development and urged the world to take note…
“Sustainable development is that which meets the needs of the
present without compromising the ability of future generations to
meet their own needs.”
This Concern Gave Birth to:
The U.S. Green Building Council (USGBC)
Initiated
the LEED System
A nationally accepted standard
for developing green buildings
The LEED system currently addresses six (6) areas of
construction. Projects opting to qualify for LEED Certification are
graded in those 6 different categories and must accumulate at
least 26 points.

67. Insulated Concrete Sandwich Walls
Sustainable Design – LEED
TM
Credit Category
Points Available
Sustainable Sites
14
Water Efficiency
5
Energy and Atmosphere
17
Materials and Resources
13
Indoor Environmental Quality
15
Total Core Points
64
Innovation and Design Process
5
LEED Certification Levels
Certified
26-32 Pts
Silver
33-38 Pts
Gold
39-51 Pts
Platinum
52-69 Pts
Within each of the 6 credit categories are several
sub-categories that create the path for scoring points

68. Insulated Concrete Sandwich Walls
Sustainable Design – LEED
TM
 Sustainable Sites
Credit 5.1
Credit 5.2
Credit 7.1
Site Development, Protect or Restore Habitat
Site Development, Maximize Open Space
Heat Island Effect, Non-Roof
Points
1
1
0
 Energy & Atmosphere
Prereq 2
Credit 1
Minimum Energy Performance
Optimize Energy Performance 15% to 60%
Required
2
 Materials & Resources
Prereq 1
Credit 1.1
Credit 1.2
Credit 2.1
Credit 2.2
Credit 4.1
Credit 4.2
Credit 5.1
Credit 5.2
Storage and Collection of Recyclables
Building Reuse, Maintain 75% of Existing Walls, Floors & Roof
Building Reuse, Maintain 95% of Existing Walls, Floors & Roof
Construction Waste Management, Divert 50% from Disposal
Construction Waste Management, Divert 75% From Disposal
Recycled Content, Use 10% (Post-Consumer + Half Pre-Consumer)
Recycled Content, Use 20% (Post-Consumer + Half Pre-Consumer)
Regional Materials, 10% Extracted, Processed and Manufactured Regionally
Regional Materials, 20% Extracted, Processed and Manufactured Regionally
Required
0
0
1
1
1
1
1
1
 Indoor Environmental Quality
Credit 3.1
Construction IAQ Management Plan, During Construction
1
 Innovation & Design Process
Credit 1.1
Credit 1.2-1.4
Credit 2.1
Innovation in Design, Use of High Volume
supplementary Cementitious Materials.
Apply for other credits demonstrating exceptional performance
TM
LEED Accredited Professional
1
2
1
LEED Silver

69. Insulated Concrete Sandwich Walls
Summary
 Benefits to Owners:
 Speed of Construction
 Limited Site Disturbance
 Attractive Appearance
 Energy Efficiency (R-30+)
 Increased Daylighting
 Long Clear Spans
 150 MPH + Low Maintenance
 Sound Transmission (STC 58)
 Moisture Management
 Fire Endurance (4-HR)
 Seismic D Rated

70. Insulated Concrete Sandwich Walls
AIA / CES Program Purpose
American Institute of Architect
Continuing Education Systems.
This concludes the CES portion of the
program. Credit earned during this program
will be reported to CES Records for AIA
members. Certificate of Completion for nonAIA members is available on request.

71. The NUFORM Building System
Specifying or Designing NUFORM?
 Think of NUFORM:
 Fully Tested & Warranted
 Complete Detail Database
 In-House AEC Support
 Valuable Team Member
 Complete specs, details, tech data,
video, samples and testing available
 World Wide Experience
 Over 100 Million Wall SF Installed
 www.nuformdirect.com