TRIP REPORT
Southern Energy Homes
Duct Tester Training, Plant Visit & Energy Star Certification

DATE
January 31, 2003

ATTENDEES
David Beal, Neil Moyer – FSEC
Michael Wade – Southern Energy Homes
Miscellaneous QC and plant/section supervisors Southern Energy Homes personal

TRIP REPORT DISTRIBUTION LIST
George James, Keith Bennett, Chris Early – U.S. DOE
D. Beal, N. Moyer, S. Chandra, J. McIlvaine, D. Chasar, R. Vieira – FSEC
Mike Mullens – UCF
Ty Batchelor, Michael Wade – Southern Energy Homes

PURPOSE

The purpose of the visit was to provide duct tester training to quality control managers, plant supervisors, section supervisors and employees. Southern Energy Homes has made a commitment that all of their factory installed duct systems will be sealed and tested to a 3% leakage rate or better.

The commitment of Southern Energy Homes also has been expanded to embrace Energy Star plant certification. Currently one of their five plants has already been certified. The four remaining plants in Alabama will be certified by mid 2003.

DESCRIPTION

      ●     January 28^th

            ◦    Classroom presentation and demonstration of the Minneapolis Duct Blaster™ to supervisors and quality control managers from each of the four Alabama plants. Instruction was provided how to perform a simple test that would provide a pass/fail indication and not delay the production line.

            ◦    Visited plant 1 (Southern Homes)

                  ■    Demonstrated in plant use of duct tester. 3 floors were tested and all were less than 3% leakage (CFM25/floor area). Mastic used on all joints and connections.

                  ■    Walked the rest of the plant to look at production process. Appears that the plant will meet Energy Star without much more than proper paper trail. There were a few areas though that should be addressed:

                                    •    No insulation depth markers installed

                                    •    Roof – wall alignments.

                                    •    Marriage line gasket detail

      ●     Visited plant 4 (Southern Homes)

            ◦    Not able to demonstrate duct tester – plant not in operation during visit. Visually inspected some of the ductwork – mastic being used on joints and connections.

            ◦    Walked the rest of the plant to look at production process. Appears that the plant will meet Energy Star without much more than proper paper trail. There were a few areas though that should be addressed:

                  ■    Marriage line gasket misalignments. Part of gasket installed on each half and appears that when assembled there will be large spans without a gasket. 

      ●     January 29^th

            ◦    Visited 2 plants (Lifestyle & Energy)

                  ■    Provided limited assistance to supervisors in duct testing as they performed test. Appears that they understand the process. Both plants used mastic on joints and connections. Both plants had less than 3% leakage.

                  ■    Lifestyle seals the boot to floor connection with mastic. This should be that standard practice adapted by all plants. Very nice application.

                  ■    Walked the rest of both plants to look at production process. Appears that the Lifestyle plant will meet Energy Star without much more than proper paper trail. Energy plant looks good. There were a few areas though that should be addressed:

                        •    Corner of the houses are sealed with expanding foam, which is not trimmed. This prevents the exterior sheathing from being in contact with the studs.

            ◦    Condensation Potential Checklist

                  ■    Michael Wade has a created a condensation potential checklist for service crews.

                  ■    Met with one of the service crews that were heading out to a couple of homes with moisture problems. Discussed the checklist and advised them on potential areas that may need to be addressed.

            ◦    Wrap-Up Meeting

                  ■    Ty Batchelor, Michael Wade

                  ■    Discussion of findings during 2-day visit

                  ■    Discussion of Energy Star certification

                        •    BOPS vs software (at this point will be using BOPS)

                  ■    Commitment to pursue EnergyStar certification

                  ■    Planning for a visit to Fort Worth TX plant late spring or early summer 2003

                        •    Energy Star certification

                        •    Duct testing in plant

PHOTOS