II. BAIHP Technical Assistance (O-P)

• Oakwood Homes
  Moultrie, Georgia
  Hillsboro, Texas
  Kileen, Texas
  Technical Support by BAIHP Researcher David Beal

BAIHP assisted Oakwood Homes with one problem home investigation between April 2003 and March 2004. This large HUD code manufacturer previously requested an FSEC duct installation review and consultation on ways to make the home’s systems work better together. In 2002, plant visits were made to the Oakwood plant in Moultrie, Georgia and to the Hillsboro and Kileen, Texas plants. Recommendations for appropriate duct system design and manufacture were reported to Oakwood Homes.

An Energy Gauge USA analysis of Energy Star and non-Energy Star homes in Boston, Minneapolis, and Indianapolis was performed. Researchers determined that Oakwood Homes could meet Energy Star standards if they increased installed gas heating and cooling system efficiencies, and floor and roof insulation levels. These results were communicated to Oakwood management via email.

• Palm Harbor Homes
  Category A, 2 Homes
  Category B, 13 Homes
  Category C, 1,645 Homes (North Carolina factories)
  Category D, 32,000 Homes
  Technical Assistance by BAIHP Researchers Subrato Chandra, Neil Moyer, Dave Chasar, and David Beal
  Awards: 2004 Energy Value Housing Award

Figure 35 A Palm Harbor Energy Star home manufactured in Plant City, Florida.

First under the Energy Efficient Industrialized Housing Program (EEIH) and now under BAIHP, FSEC collaborates with Palm Harbor Homes (PHH) offering building science advice, energy ratings, and conducting diagnostic testing including infrared building and duct air tightness thermal imaging camera inspection. As a result, PHH now incorporates added return air transfer ducts to minimize pressure imbalances in the conditioned space and measures leakage of every duct system to ensure losses below 3% (Qn total) at every factory.

FSEC provided assistance to Bert Kessler (PHH VP of Engineering) with submission of an NAHB nomination for the 2004 Energy Value Housing Award.

Energy Star Plant Certification for Palm Harbor Factories nationwide

With FSEC guidance, PHH Plant City produced the world's first two HUD-code Energy Star homes in 1997 (Figure 35). Since then, EPA has implemented an Energy Star factory certification procedure which involves testing in both the factory and at the home sites. The procedure verifies consistent factory production of Energy Star level manufactured homes.

Nine Palm Harbor factories have completed certification (Table 20) under the new Energy Star guidelines for manufactured homes.

Energy Star Ratings using EnergyGauge USA

In the fifth budget period, FSEC rated two PHH modular homes produced in Texas. Prior to that, FSEC staff conducted several Energy Gauge ratings and related energy analyses for PHH Plant City (FL) and performed two energy analyses comparing standard HUD code specifications to PHH energy improved homes sited in Detroit, Morgantown (WV), and Missoula (MT).

EnerGMiser Energy Management System

Researchers conducted an analysis of the PHH EnerGMiser Energy Management System and quantified the energy savings over base-case HUD code homes in 40+ US cities. Energy savings ranged from 28% to 42%. The results of these analyses are listed at the PHH corporate web site at www.palmharbor.com/our_homes/home_features/energy_management_system.

Factory in Albemarle, North Carolina

FSEC contacted the North Carolina engineering manager for information on Palm Harbor's typical model construction specifications in order to begin Energy Star qualifying procedures. Two PHH model analyses for three different climate zones were run to assess initial energy efficiency. These tests were rerun once specific window SHGCs were received from PHH.

On February 24 and 25, 2003, FSEC conducted a plant visit to direct and oversee Energy Star certification tests on six floor models. Tests were completed by FSEC and by factory personnel with FSEC oversight. All models passed the 3% leakage limit. To complete the certification, three additional site installed homes will be tested for compliance.

FSEC staff also worked with the plant engineer on builder option packages (BOPs) versus software options as a means to qualify homes for Energy Star. It was determined that qualifying homes in Energy Star zones 3 and 4 will be feasible using BOPs, but EG USA will be needed to certify at least some of the zone 2 homes.

Factory in Austin, Texas

PHH initiated certification procedures for Energy Star per the EPA/MHRA guidelines. Staff completed the reporting and certification on two PHH Austin homes in the Houston area for Energy Star compliance. One home passed and the other failed due to belly board installation problems. (Figures 36 and 37) These belly board problems have since been addressed and the Austin plant and the remaining three Texas plants are currently being certified for Energy Star production.

Figure 36 Another belly tear found during inspection .	Figure 37 Worst belly tear near plumbing penetration .

Factory in Plant City, Florida

Energy Star Plant Certification

Researchers initiated certification procedures for Energy Star per the EPA/MHRA guidelines. FSEC reviewed the Design Approval Inspection Agency (DAPIA) packages and design procedures. The PHH Plant City factory was certified in February 2003 and registered one Energy Star home in Polk County, Florida.

FSEC met with the plant engineer on September 16 and 17, 2002 to analyze several new models for Energy Star eligibility. The analysis was conducted using EG USA software (v-1.32). Researchers assisted the plant engineer with a combination of EG USA software and BOPs, so that all plant models over several states could reach Energy Star levels.

Insider Heat Pumps

In 2001, five model homes at PHH-Plant City were tested for return air performance. Two of the homes were modular with Insider heat pumps. Performance results and recommendations were submitted to the plant engineer.

Staff retested two modular homes with Insider heat pumps and determined that leakage in the condenser fan compartment was depressurizing the homes. Further testing on other Insider installations is needed to uncover the scope of this problem and plans are in progress to find the best corrective course of action. BAIHP will visit PHH Plant City and observe the installation when the next Insider heat pump is requested. Researchers will look for installation problem areas and perform additional home tests.

Technical Assistance

Diagnostic tests were conducted in 2002 and 2004 on home s in Odessa and Plant City , Florida manufactured by PHH-Plant City. Th ese visit w ere requested by PHH after they received a homeowner high-utility bill complaint s . In Odessa, i nspections with the infrared (IR) camera found no insulation problems and duct blaster and blower door tests revealed airtight duct and envelope systems. Other than an oversized air conditioning system, there were no obvious reasons for the high bills. The homeowner was satisfied with the investigation and apologized for their written complaint. In Plant City, problems with the sizing of the field-installed A/C ducting had caused temperature differences in the home. PHH redid the ducting and BAIHP hasn’t heard further complaints.

Building America Homes

Palm Harbor Plant City built two homes that meet or exceeded current Building America energy goals, one study home used in the Manufactured Housing Indoor Air Quality (IAQ) study detailed in Section III, and a high visibility modular home built for the 2005 International Builders Show (IBS) in Orlando FL. Both homes were built in cooperation with BAIHP researchers. The IAQ house’s HERS score was 91.1, the IBS building scored a 93. The IAQ home demonstrated a 50% saving in A/C energy compared to an Energy Star rated home (HERS of 86.5) used for control in the same experiment. The IBS showhouse is detailed in the Technical Assistance section under “International Builders Show Showhouses.”

Factory in Sabina, Georgia

PHH signed an Energy Star Partnership Agreement to begin certification of the Sabina Plant. Two model home plans were analyzed, each with a gas furnace and a heat pump, using EnergyGauge USA software. The plant certification visit and site-installed home ratings were done in Spring 2002 and certification paperwork was forwarded to the EPA for plant registration. PHH is planning a 54-unit development in Wilmington, Ohio. Modifications made at the Sabina Plant should be very helpful for the Wilmington endeavor.

• Patrick Family Housing, LLC
  Satellite Beach, FL
  Technical Assistance by FSEC, Calcs-Plus

The group represents a partnership between the US Air Force and American Eagle Communities, and is handling a housing privatization project, taking place on Patrick Air Force Base in Satellite Beach, FL. Plans are underway to construct several hundred single-family housing units, which will be leased to Air Force personnel. BAIHP is providing design assistance to the project, and will closely monitor construction of 5 prototype homes.

BAIHP researchers met with partner Patrick Family Housing to discuss mechanical design issues in five model homes, and coordinated a review of HVAC design and system sizing for partner Patrick Family Housing. Review and design analysis conducted by partner Calcs-Plus. Advice was given to adapt systems to Florida’s hot-humid climate.

FSEC staff visited the site where 5 prototype homes are being constructed. Five slabs have been poured, and wall and roof structure erected for one home. Builder feedback was received on the use of a solid pour wall system, and recommendations on insulation, stucco application, and attic venting were provided.

• Penn Lyon Homes
  Selinsgrove, Pennsylvania
  Technical Assistance by BAIHP Contractor University of Central Florida, Industrial Engineering Department

Figure 38 Scanning drywall activities with new STACs device.

In March of 2004, Penn Lyon Homes (Selinsgrove, PA) began a large scale plant wide test of a prototype Status and Control System (STACS) developed by BAIHP researchers at the UCF Constructability Lab. The system is a real time shop floor labor data collection and reporting system. Production workers use wireless laser scanners (Figure 38) to report their current work assignment.

STACS reporting is web based and provides both real time manufacturing status and summaries of historical production performance. While labor represents a relatively modest fraction of production cost, typically 10-15%, it has a profound impact on operations, including product quality, cycle time, material waste, and labor productivity. The test will continue through the summer of 2004, and results will be used to develop labor models using linear regression and neural nets.

See also, Avis American Homes (Technical Assistance section) and Status and Control System (STACS) (Section III, Research).

• Podia Construx/Rainbow Springs Construction
  Gainesville, Florida
  Category B, 22 Homes
  Technical Support by BAIHP Subcontractor: Florida H.E.R.O.

Florida H.E.R.O. worked with David Sullivan, owner of Podia Construx, his sales staff, project management, and principal sub-contractors to incorporate Building America concepts into the communities of Rainbow Springs, Hidden Lake, and Ocala Waterway.

Podia builds mostly concrete block homes with a continuous, interior layer of ¾” unfaced rigid wall insulation and unvented attics. Spray foam insulation is applied to the underside of the roof deck and is sometimes used for wall insulation. Some of Podia’s homes are performance tested for duct and whole house air tightness. The homes also feature SEER 13 heat pumps or SEER 13 air conditioners coupled with standard gas furnaces. All homes have filtered outside air ventilation and double pane Low-E vinyl frame windows.

Podia tried replacing roofing felt with Tri-Flex material for moisture transmission reduction on home, but after complaints from the roofers regarding a lack of footing on the slick material, the Tri-Flex was removed and replaced with standard felt paper.

Condensation Complaint

In response to a homeowner’s concern about excessive condensation on interior windows, Florida HERO performed a site survey of ambient, interior, surface, and subsurface moisture readings to determine the cause. This home has Icynene sprayed on the underside of the roof sheathing and an outside air duct. The outside air duct damper had been shifted to the closed position. The damper was reopened and the moisture related complaints were eliminated.