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Structural insulated panels (SIPs) are high performance building panels used in floors, walls, and roofs for residential and light commercial buildings. The panels are typically made by sandwiching a core of rigid foam plastic insulation between two structural skins of oriented strand board (OSB). Other skin material can be used for specific purposes. SIPs are manufactured under factory controlled conditions and can be custom designed for each home. The result is a building system that is extremely strong, energy efficient, and cost effective that replaces traditional framing, insulation, and sheeting. Building with SIPs will save you time, money, and labor.
How does the SIP design and fabrication process work? Click to view answer.
We would be happy to answer any questions you have in the design phase. The construction of a SIP home or commercial building begins with the construction documents. Once the construction documents are in our hands, they are converted to SIP shop drawings that give the dimensions of each individual panel needed to complete the job. A work order and contract are generated and sent with the shop drawings to the builder, the building owner, and other involved parties for review. Once the work order and contract are finalized, the SIPs are fabricated and shipped to the jobsite for installation.
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R-values for SIPs depend on the thickness of the SIP. See our R-value comparison for the minimum R-values by SIP size. Static R-values, like those included in the chart, rate the effectiveness of insulating material. However, they do not accurately describe how products perform in a real world setting. When fiberglass or other types of insulation are installed, they are installed around structural members made of wood or metal which have a very poor insulating value. Field-installed insulation materials are also prone to installation imperfections. The Department of Energy’s Oak Ridge National Laboratory has studied and tested the performance of entire wall assemblies in large sections. The resulting whole-wall R-value data reveals that a 4.5” SIP wall rated at R-14 outperformed a 2”x6” wall with R-19 fiberglass insulation.
How green are structural insulated panels?
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Energy efficient structural insulated panels are one of the most environmentally responsible building systems available. A SIP building envelope provides high levels of insulation and is extremely airtight, meaning the amount of energy used to heat and cool a home can be cut by up to 50%. The energy that powers homes and commercial buildings is responsible for a large portion of greenhouse gasses emitted into the atmosphere. By reducing the amount of energy used in buildings, architects, builders, and homeowners can contribute to a clean environment for the future.
How strong are structural insulated panels?
Resource use The insulation used in SIPs is a lightweight rigid foam plastic composed of 98% air and requires only a small amount of petroleum to produce. The foam insulation used in panel cores is made using a non-CFC blowing agent that does not threaten the earth’s ozone layer. Add % energy saved over fiberglass insulation. Add % less wood used by OSB over traditional framing. Waste minimization Since SIPs are prefabricated in the factory, there is less jobsite waste that needs to be landfilled. Factory fabrication is done using optimization software and we recycle factory scrap to make other foam products. Click to view answer.
The structural characteristics of SIPs are similar to that of a steel I-Beam. The OSB skins act as the flange of the I-beam, while the rigid foam core provides the web. This design gives SIPs an advantage at handling in plane compressive loads. SIPs can be engineered for most applications.
How are structural insulated panels supported? Are there studs in the panels?
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For most applications, SIPs are structurally self-sufficient. The structural characteristics of SIPs are similar to that of a steel I-Beam. The OSB skins act as the flange of the I-beam, while the rigid foam core provides the web. This design is extremely strong and eliminates the need for additional framing. In cases where a point load from a beam or header requires additional support, a double dimensional lumber spline is field-installed at in-plane panel connections. SIPs are also used as curtain walls for steel frame or timber frame structures. In large commercial applications SIPs can minimize the amount of structural support needed and reduce material costs. In roof applications, SIPs can span long distances, allowing a minimal amount of structural supports to be used. Where needed, SIPs can rely on beams and purlins for support.
How do I properly size HVAC equipment?
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The high insulating properties of SIPs allow smaller HVAC equipment to be used. When working with an HVAC contractor, make sure their calculations take into account an accurate estimation of the typically low levels of air infiltration in a SIP home. Proper HVAC sizing is crucial because an oversized HVAC system will fail to reach the steady operating rate the equipment was designed for. Short cycling HVAC equipment will be less energy efficient and require more maintenance than properly sized HVAC equipment.
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The tightness of the SIP building envelope prevents air from gaining access to the interior of the home except in controlled amounts. A controlled indoor environment is both healthy and comfortable. Humidity can be controlled more easily in a SIP home resulting in a home that is more comfortable for occupants and less prone to mold growth and dust mites. Click to view answer.
Residential building code requires that foam insulation be separated from the interior of the building by a material that remains in place for at least 15 minutes of fire exposure. Structural insulated panels faced with 0.5” gypsum drywall meet this requirement. Click to view answer.
SIPs are compatible with other building systems. Wall panels can sit on a variety of foundation materials, including poured concrete, blocks, or insulated concrete forms. SIPs are sized to accept dimensional lumber and are seamlessly compatible with stick framing. Builders may choose to build with SIP walls and a conventional truss roof, or stick walls and a SIP roof with little difficulty. SIPs are also popular as a method of providing a well-insulated building envelope for timber frame structures. Click to view answer.
Electrical wires are pulled through pre-cut channels inside the core of the panels called “chases.” We cut chases during the manufacturing process according to the electrical design of the home. Electricians can then use fish tape to feed wires through panel chases without compressing the insulation or having to drill through studs. Wiring can also be run through baseboard raceways and in the cavity behind the beveled spacer on SIP roof-to-wall connections. Click to view answer.
As with conventional framing, plumbing should not be located in exterior SIP walls because of the possibility of condensation or supply lines freezing in cold climates. During the design phase of the project, all plumbing should be relocated to interior walls. If plumbing must be located on an exterior wall, it is recommended that a surface chase be installed on the interior of the wall to conceal plumbing. Plumbing penetrations such as DWV can be placed through SIPs if they are thoroughly sealed to prevent air infiltration.
Can recessed lights be used in structural insulated panels?
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Recessed lights should never be embedded in structural insulated panels. To install recessed lights, an interior soffit must be constructed.
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Cabinets are attached to SIPs all the time. It is, however, recommended that the cabinet manufacturer provide instructions on how to attach their product to SIPs. Typically, an increased fastener schedule is required. Another option is to install plywood strips behind the cabinets to provide additional holding strength for fasteners. If the cabinet manufacturer does not offer recommendations for attaching their product to SIPs, a licensed architect or engineer can calculate the appropriate fastener frequency.
Do roofing manufacturers warranty asphalt shingles over structural insulated panel roofs?
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Some roofing manufacturers warranty asphalt shingles over unvented SIP roofs, while others void their warranty because of higher shingle temperatures. Research conducted by Building Science Corporation reveals that although asphalt shingle temperatures increase slightly (2o - 3o F) in an unvented roof assembly, the color of the shingles and the roof orientation have a much more profound impact on the durability of shingles. According to the Builder’s Guide to Structural Insulated Panels (SIPs) published by Building Science Corporation, the typical reduction of shingle life over an unvented SIP roof assembly is between one and two years. Builders seeking to comply with roofing manufacturer warranties can choose from a variety of more durable, non-asphalt roofing materials or provide a venting space between the SIP roof panels and the roofing material (known as a cold roof).
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