When Bill Churchill set out to build his 4,000 square-foot Sudbury, MA home, his objective was to apply standardized industrial manufacturing technologies to achieve a residence with superior thermal and energy efficiency. Using Kingspan Insulated Panels’ KingZip® Insulated Standing Seam Roof panels and 300 A Azteco® Embossed wall panels, Churchill was able to create an energy efficient building envelope and better insulate his home.
“As I began evaluating building products, I set out to find the most insulated panels for the New England climate,” said Churchill. “I spoke with Metro West Steel, the contractor and installer, for recommendations and Kingspan’s panels were extremely well priced for the thermal resistance that I would achieve using them. Typical stick built residential construction gives you an R-value of about 20. With 5-inch thick Kingspan roof and wall panels I am achieving an R-value of 41. Using traditional construction I would have had to build two walls to attain that rating.”
Sudbury, located 20 miles west of Boston, experiences winter temperatures that often drop below zero degrees Fahrenheit. To help keep the home and its occupants warm, Kingspan’s KingZip Insulated Standing Seam Roof panel features a two-piece thermally broken concealed clip design that helps minimize heat loss through the sidejoint and the possibility of condensation at the clip assembly. With five thickness options available, KingZip can achieve R-values up to 49.
To provide additional thermal efficiency, Churchill used 5,048 square-feet of the 300 A Azteco Embossed wall panel. Available in six thickness options, the 300 A can also achieve R-values up to 49. With the insulation already foamed in place, 300 A is an economical flat wall system for metal building systems.
Other energy efficient elements of the project includes polished concrete floors, foam insulation in the concrete foundation and a Tulikivi soapstone fireplace, which retains the thermal energy from the fire in the soapstone mass and radiates heat for 12 – 14 hours. Churchill also installed highly energy efficient windows throughout the house, taking advantage of natural daylighting and solar heat gain by installing large south-facing windows. Additionally, KingZip’s interior liner presents a bright, reflective, washable surface to help reduce lighting requirements.
As construction continued, Wrentham, MA-based Metro West Steel worked to get the steel framing and panels installed quickly to beat the cold, New England winter. KingZip panels are pre-engineered as a single component with the insulation already foamed in place, allowing for single-step installation. The Kingspan panels arrived on site pre-fabricated ready to be installed. Both KingZip and 300 A Azteco are 42-inches in width, making them easy to handle and position and allowing fast installation.
“This project was incredibly unique,” said Dino C. Cauteruccio, sales manager for Metro West Steel. “Because we were basically creating a commercial building to be used as a residence, there were days that it felt like being on a roller coaster and not knowing the ride. Everybody involved in the project was incredible and open-minded about the details involved. Although we are familiar with insulated metal panels, this project addressed the use of the panels in a new way. It really opened up a world of possibilities.”
Churchill and his family moved into the house in August 2009. From the time foundation was laid until move-in, the process took 12 months. Churchill is seeking Leadership in Energy and Environmental Design (LEED®) certification for his home. Insulated metal panels can contribute to LEED certification potentially earning points in energy and atmosphere, indoor environmental quality, innovation in design and material and resources. KingZip can also help meet the requirements for ENERGY STAR® and Cool Roofs.
“I haven’t yet experienced a winter in the completed house, but feel confident that we will be able to stay warm while conserving energy,” said Churchill. “Because there are very few templates for homes like this, I worked closely with Kingspan and Metro West to map out the details. I truly believe that the building envelope is the key ingredient to sustainable design and plan to use my home as a template for future projects like this one.”
Photo courtesy of Damiano's Photography