AIA PRESENTATION is a Registered Provider with the American Institute of Architects Continuing Education Systems. Credit earned on complet\൩on of this program will be reported to
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Slide 1 of 42 AIA PRESENTATION Insulated Metal Wall and Roof Panels for Sustainability and Energy Efficiency IMP001 1 LU/HSW Hour
Insulated Metal Wall and Roof Panels for Sustainability and Energy Efficiency IMP001 1 LU/HSW Hour
Presenter
Presentation Notes
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Best Practice
MBCI is a Registered Provider with the American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-AIA members are available upon request. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be 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.
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Presenter
Presentation Notes
MBCI is a Registered Provider with the American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-AIA members are available upon request. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be 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.
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Learning Objectives
At the end of this program, participants will be able to:
• explain how IMPs lower building energy costs, prevent moisture intrusion and improve the thermal comfort of the occupants
• compare the insulating values of IMPs to traditional systems and illustrate how IMPs reduce the carbon footprint of a building
• analyze the sustainability and performance criteria of IMPs relative to qualifying for credits under today’s green building rating programs
• discuss how IMPs serve as walls, ceilings and roofs in new and retrofit construction, and how they can be easily adapted to pre-engineered metal building designs, and
• differentiate various types of IMPs based on their performance
attributes and aesthetics
Presenter
Presentation Notes
Learning Objectives At the end of this program, you will be able to: explain how IMPs improve building performance by lowering energy costs, preventing moisture intrusion and improving the thermal comfort of the occupants examine the durability, energy efficiency and thermal performance of IMP systems by comparing their insulating values to traditional systems of the past and illustrating how IMPs reduce the carbon footprint of a building analyze the sustainability benefits, attributes and performance criteria of IMPs relative to qualifying for credits under today’s green building rating programs discuss how IMPs serve as walls, ceilings and roofs for commercial and industrial buildings, in new and retrofit construction, and how they can be easily adapted to pre-engineered metal building designs, and differentiate various types of IMPs based on their performance attributes and aesthetics, and specify the appropriate IMP system for a specific application.
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Why Insulate?
To create a wall with high thermal performance the following issues must be controlled: • air leakage and infiltration • thermal bridging • gaps in insulation* • condensation
*In 2013, ASHRAE 90.1 2010 will require continuous insulation in all regions.
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Presentation Notes
1.Introduction to IMPs Why Insulate? There are a myriad of elements and assemblies that go into creating a high R-value wall, one that reduces annual heating and cooling costs; provides comfortable, healthy interior environments; prevents air leakage and filtration; and protects against fire. Simply providing an adequate amount of insulation is not enough. Issues like air leakage, thermal bridging, and condensation within the wall must be considered to ensure the creation of a wall with a high thermal performance. Continuous insulation (insulation external to the building structure) eliminates thermal bridges that greatly reduce whole wall R-value. A steel stud wall assembly with batt insulation will lose 75% of its R-value through thermal bridging. Continuous insulation is currently required under ASHRAE 90.1 2007 in some regions, and in 2013, ASHRAE 90.1 2010 will require continuous insulation in all regions. The second part of a good wall design is to limit air leakage and infiltration by providing good and properly placed air and vapor barriers. Controlling air leakage increases whole wall R-value; provides comfortable, healthy interior environments; and protects the building envelope from moisture intrusion and subsequent degradation of building components and materials.
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Insulated Metal Panels
• A form of continuous insulation - rigid urethane foam sandwiched between two sheets of coated metal
• IMPs serve as walls, ceilings and roofs for commercial and industrial buildings, in new and retrofit construction
Roof panel Wall panel
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Presentation Notes
1. Introduction to IMPs Insulated Metal Panels Insulated metal panels (IMPs) in their simplest form are rigid urethane foam sandwiched between two sheets of coated metal. These panels, with an impermeable steel panel facing encapsulating the insulating material, create a vapor barrier—thereby providing long-term thermal stability and reducing the carbon footprint of a structure. As a form of continuous insulation, IMPs provide a uniform insulating value and offer one of the highest insulating values per inch, for both vertical and horizontal applications. This presentation discusses how IMPs improve the energy efficiency and contribute to the sustainability of a building. Commercial and Industrial Panel Systems Commercial and industrial IMPs serve as walls, ceilings and roofs for commercial and industrial buildings, in new and retrofit construction. They can be easily adapted to pre-engineered metal building designs for almost any end-use as walls and roofs, saving material and labor costs. Their skins are durable, and the panels are formed in a variety of styles and sizes depending on application. IMP systems offer design professionals the opportunity to design functional, attractive, sustainable buildings, and building owners the opportunity to lower construction, operating, energy consumption, and maintenance costs throughout the life span of a building.
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Applications
• Schools, hospitals, religious facilities, office buildings, aircraft hangars, manufacturing facilities, distribution warehouses, equipment screens and maintenance buildings, mechanical penthouses, prison units
Lapel High School
Million Air Charleston
Gary Jet Center
Nanaimo Ice Center
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Presentation Notes
1. Introduction to IMPs Applications Additional end applications include schools, hospitals, religious facilities, manufacturing facilities, distribution warehouses, equipment maintenance buildings, mechanical penthouses, kiosks, equipment screens, aircraft hangars, prison units and office buildings.
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IMP Systems Compared to Other Panel Systems
• IMP systems provide many of the same benefits found with other metal wall and roof systems, plus some unique benefits found only with IMPs
• IMPs are composite, factory-insulated, all-in-one, single-element panels with factory-applied coatings
• IMPs are lighter in weight, easy to install, and allow for faster
building completion, all year round in almost any kind of weather
• No risk to system integrity since IMPs have few field-
assembled components with no multiple installation steps
Presenter
Presentation Notes
1. Introduction to IMPs IMP Systems Compared to Other Panel Systems IMP systems provide many of the same benefits and features found with other metal wall and roof systems, plus some unique benefits found only with IMPs. IMPs are composite, factory-insulated, all-in-one, single-element panels which arrive at the construction site pre-painted with a high-performance, factory-applied coating. Lighter in weight compared to other wall and roof systems, they are easy to install and allow for faster building completion, all year round in almost any kind of weather. There is no risk to system integrity since IMPs have few field-assembled components and do not require multiple installation steps—which may occur in the field with other insulated wall and roof systems.
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Core Insulation
Polyurethane and polyisocyanurate have similar physical properties for: • compressive strength • tensile strength • shear strength • minimum closed cell content • foam density
Type of blowing agent used will impact whether polyurethane or polyisocyanurate foam is used to make IMPs.
Cell structure
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Presentation Notes
2. Sustainable, Integrated Components Core Insulation The physical properties for polyurethane and polyisocyanurate are very similar—so what is the difference? Polyurethanes are produced by an exothermic chemical reaction between liquid polyol and polymeric isocyanate. The foam recipe for polyol contains polyol, blowing agent, catalysts and surfactants, which are premixed in temperature controlled tanks and then mixed with isocyanate to initiate the chemical reaction. It is then injected between metal faces and bonds to the surfaces to form a continuous panel. The polyol portion of the polyurethane can be sourced from sugar beets. Components in some IMPs use sucrose from sugar beets to replace petroleum-based products. Commercially available polyisocyanurates are made from isocyanate, catalysts, blowing agent and surfactants, modified with polyurethane. The resulting mixture is poured as a liquid between metal faces. The liquid expands to form solid cellular foam that bonds to metal faces to form a continuous panel. If the two foams, polyurethane and polyisocyanurate, appear similar in their components and method of manufacture, they are. The type of blowing agent incorporated in the manufacturing process has a significant impact on whether polyurethane or polyisocyanurate foam is used to make IMPs. Regardless, rigid polyurethane and polyisocyanurate foams have the highest insulating value per inch of all commercially available foam insulation products today. The panel core chemistry is usually proprietary to each manufacturer.
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Blowing Agents
• Common hydrocarbon (HC) blowing agents are pentane isomers (Neopentane, Isopentane and Cyclopentane)
• Pentane isomers have zero ozone depleting potential and provide good thermal performance
• HFCs are non-volatile organic compounds, and provide superior dimensional stability and a high thermal performance
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Presentation Notes
2. Sustainable, Integrated Components Blowing Agents The most common hydrocarbon (HC) blowing agents are pentane isomers, such as Neopentane, Cyclopentane and Isopentane. All three pentane isomers have zero ozone depleting potential (ODP) and provide good thermal performance. HFC 134a and HFC 245fa hydro-fluorocarbons are non-flammable, non-ozone depleting products. HFCs are also a non-volatile organic compound (VOC). HFCs provide superior dimensional stability and a high thermal performance, especially at low temperatures. HFC 134a has a small aggregate radiative forcing impact on global warming and no EPA (U.S. Environmental Protection Agency) limits on its use today and into the future.
2. Sustainable, Integrated Components Panel Facings The standard gauge for roof panels is 24 or 26. Heavier gauges are not necessarily required for structural integrity, although 22 ga. is readily available from most manufacturers. The steel is either G-90 galvanized or has an aluminum-zinc coating that provides sacrificial protection to the steel surface. Stainless steel is frequently used for the inside face of the panel in food processing plants, where paint finishes, when used, are subjected to heavy wash-down conditions with high-pressure water and abrasive chemicals. Both interior and exterior faces of the panel are typically embossed to reduce the appearance of oil canning. It is recommended, however, that the inside face of panels used in heavy wash-down areas not be embossed to help extend the useful life of the coating. Steel faces on IMPs contain recycled content, often more than 30%. Of this, post-consumer recycled content may be more than 20%, and pre-consumer recycled content is 7% or higher. The polyurethane foam core has a pre-consumer recycled content of approximately 7% and 0% post-consumer. Steel used for single-skin wall panels may contain an average post-consumer recycled content of 25% and an average pre-consumer recycled content of 6.8%. In addition, because of the durability and ease of installation of IMPs, panels can be easily disassembled, moved and reused for the interior or exterior walls of a new project or building expansion.
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Finish and Coatings
• Panels are prefinished on both the interior and exterior faces
• Coatings provide protection
against UV rays, corrosion, humidity, acid rain, and a wide range of chemicals and other pollutants
• Coatings provide gloss retention, and resist chalking, fading, chipping, and dirt
Presenter
Presentation Notes
2. Sustainable, Integrated Components Finish Insulated metal wall and roof panels are typically prefinished on both the interior and exterior faces. The typical exterior finish is the industry standard nominal 1.0 mil (inclusive of primer) PVDF (70% Kynar® 500/Hylar® 5000). A silicone modified polyester paint is commonly used as the exterior finish on cold storage buildings. The typical interior finish is a nominal 1.0 mil (inclusive of primer) standard polyester, in a light-reflective, easy-to-maintain white color. Special high-build coatings are available on both the interior and exterior faces of the panels to provide added protection in extreme environments. A benefit of incorporating an IMP system into a building envelope is that the liner side of the panels may be used as the interior finish. Coatings IMP coatings are formulated to provide protection against UV rays, corrosion, humidity, acid rain and a wide range of chemicals and other pollutants. Specific formulations will protect a building in exceptionally harsh environments, such as those found in seacoast and industrial locations where maximum salt spray and chemical corrosion protection is needed. Interior coatings provide easy cleaning and washing, as well as high light reflectivity. In addition, the coatings provide gloss retention and resist chalking, fading, chipping and dirt.
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Cool Roofs
• Cool roofs help mitigate global warming and reduce urban heat islands and smog • they reflect (solar reflectance) and
radiate (thermal emittance) the sun’s heat away from a building
• Insulated metal roof panels with a
white Fluropon® exterior skin meet the definition of cool roofing for low-slope roofing under Title 24, Part 6 of the California Energy Code in 2005
Cool Roof Rating Council, www.coolroofs.org
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Presentation Notes
2. Sustainable, Integrated Components Cool Roofs Cool roofs help to mitigate global warming and reduce urban heat islands and smog, because they reflect (solar reflectance) and radiate (thermal emittance) the sun’s heat away from a building. The 2010 version of the ASHRAE 90.1 energy code makes cool roofs a prescriptive requirement for Climate Zones 1 through 3. Insulated metal roof panels with a white Fluropon® exterior skin are CRRC licensed and meet the definition of cool roofing for low-slope roofing under Title 24, Part 6 of the California Energy Code in 2005. In order to meet the definition of “cool” under the new Title 24 requirements in 2005, low-sloped commercial roofs must have an initial reflectance and emittance of at least 0.70 and 0.75, respectively, as rated by the Cool Roof Rating Council, www.coolroofs.org.
2. Sustainable, Integrated Components Panel Production The manufacturing process of IMPs requires mechanical equipment and a knowledge of foam chemistry. The continuous process, shown on the next slide, entails forming the continuous metal facers while at the same time (at another point on the continuous line) injecting the foam mixture into the panel assembly. The metal for the interior and exterior faces is heated. It then passes through roll-formers to profile the faces and form the side joints. The foam is then injected as a liquid or froth between the faces and begins to rise and chemically bond to the metal skins, completely filling the interior cavity and creating a solid, monolithic panel. The heat curing chamber is about 100' long. When the panel exits the chamber, it has already set, but still requires additional cure time in a temperature controlled environment. After exiting the chamber, panels are cut by a flying saw, side conveyed and sent to the packaging area. These lines are ideally suited for continuous manufacturing of panels having the same thickness, module width, color and profile.
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Panel Description and Installation
• Installation savings – single-element panels, fewer side joints
• Weather-tight performance • Installation from top side of roof
• Engineered end laps for long
runs from ridge to eave
• Foam core 2" to 6" • Module widths 30", 36", 42" • Standing seam mechanically closed • Concealed fastening • Engineered end lap • Low pitch ½" in 12"
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Presentation Notes
2. Sustainable, Integrated Components Panel Description and Installation Roof panels have a foam core made of polyurethane or polyisocyanurate, and standing seam designs with either a single lock or key-hole lock for weather- tightness. Standing seam insulated panels are typically available in module widths from 30" to 42". The expansive panel width options contribute to installation savings because there are fewer side joints to seal compared to single-skin standing seam roof panels. Additionally, panels are installed as a single element that greater contributes to installation savings. The panels are attached with concealed side joint clips and fasteners, and the seam is mechanically closed to ensure weather-tight performance. This permits installation completely from the top side of the roof. The panels have engineered end laps for long runs from ridge to eave. The end laps have a factory-cut back of the bottom skin and foam, and then the ends are notched and swaged, which eliminates critical and extensive field reworking of the panels.
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Panel Description and Installation
• Self-contained units of roof weather membrane, roof insulation, and liner/decking
• Batten lap seams and ribbed
panel widths range from 1m to 40" • Standard max. panel length is 50'
• End of panel supported by roof
structure
• Lapped faces use gasket-type joints
Lap seam
Ribbed
Presenter
Presentation Notes
2. Sustainable, Integrated Components Panel Description and Installation Batten lap seam and ribbed panels are offered in module widths typically ranging from 1 meter to 40". Available thicknesses range from 2" to 6". The panels are self-contained units of roof weather membrane, roof insulation and liner/decking. This provides factory control of the roof’s materials, fit-up and performance. This also provides the efficiency and control of a single source and single trade installation for the complete roof system. The typical standard maximum panel length is 50'. End laps are required for longer runs from ridge to eave. End laps consist of an extension of the top metal skin of the panel and butt-joining of the foam core and the bottom skin. The end of each panel is supported by the roof structure. The lapped faces are sealed with specially designed sealants and fasteners to create a gasket-type joint that effectively prevents water penetration.
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Architectural Wall Panels
• Provide flush, high-profile, clean appearance
• Combine well with window systems
• Formed side joints – hidden application of vapor sealant
• Concealed attachments with clips and fasteners
• Trimless ends
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Presentation Notes
2. Sustainable, Integrated Components Architectural Wall Panels Attached with concealed clips and fasteners in the side joint, architectural wall panels provide a flush appearance. When applied horizontally, architectural wall panels combine well with window systems. A formed side joint permits hidden application of the vapor sealant within recessed grooves. This panel design protects the sealant from the harmful effects of extreme weather, will not attract dirt and provides for an impenetrable water and vapor seal. The concealed attachment with clips and fasteners at the side joint of the panel offers a clean, high-profile appearance. Trimless ends complement the high-profile appearance of horizontally installed panels. The vertical joint in horizontal applications of the architectural wall panel utilizes a dry gasket that helps maintain a clean, weather-tight seal and remains in place even under the most severe weather conditions. Custom and standard IMPs are available in a variety of colors, textures, and finishes to meet the aesthetic requirements of any building project.
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Exterior cladding i.e. single-skin metal panel
High-performance continuous insulation metal barrier wall panel
Steel Stud
High-Performance Continuous Insulation Panels
• Provides air, water, thermal and vapor protection in a single-panel component
• No thermal bridges
• Quick and easy to install behind any type of façade
• Separated from the interior of the building by an approved thermal barrier
Gypsum Board
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Presentation Notes
2. Sustainable, Integrated Components High-Performance Continuous Insulation Panels The innovative design of a high- performance continuous insulation metal barrier wall panel provides air, water, thermal and vapor protection in a single-panel component. It can be used behind any type of façade, such as metal or brick, and is installed in a horizontal orientation completely outside the structural supports, so there are no thermal bridges to reduce the energy efficiency of the wall. This type of IMP is quick and easy to install and provides an economical solution to conventional air, water, thermal and vapor control without sacrificing thermal efficiency. It must be separated from the interior of the building by an approved thermal barrier of .5" (12.7mm) gypsum wallboard to meet IBC requirements
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Testing Requirements
IMPs are tested and carry ratings for: • fire • structural • thermal transmittance • foam core properties • water penetration • air pressure differential
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Presentation Notes
3. IMP Performance Testing and Design Benefits Testing Requirements The purpose of wall and roof IMPs is to insulate a building and protect it from the outside elements. The systems improve the performance efficiency of the building envelope and contribute to today’s building sustainability requirements—an important step in achieving net-zero buildings. IMPs are manufactured to meet the performance and testing requirements of the model building codes and insurance listing agencies. Consult individual manufacturers for further information. � IMPs are tested and carry ratings for: fire structural thermal transmittance foam core properties water penetration, and air pressure differential
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Thermal Performance
• Panel faces and metal trim completely encapsulate insulation
• Consistent R-values maintained across entire wall and roof areas
• Consistent R value over life of panel
• Insulation is never compressed
• Complete concealed fastener system
• No thermal bridging from exterior to
interior skin
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Presentation Notes
3. IMP Performance Testing and Design Benefits Thermal Performance IMPs offer high insulation values and built-in thermal breaks that provide lower heating and cooling costs to the building owner. The insulation is completely encapsulated by the panel faces and a metal trim, which creates an impermeable membrane on all sides of the panel. This means there are no gaps or voids to degrade thermal value, and no diffusion by air or moisture. IMP wall and roof panels are installed completely outboard of the supporting structure, and the tongue and groove joinery ensures that consistent R-values are maintained across the entire wall and roof area. Insulation thickness is maintained between the metal panels; there are no areas where the insulation is compressed, causing a reduction in overall thermal value. IMPs offer a complete concealed fastener system that includes the vapor, air and water barriers, along with a high-efficiency insulation system. Thermal performance is enhanced, since there is no thermal bridging from exterior to interior skin.
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Thermal Efficiency and R-Value Comparison
R-value for 1" of material: • Polyurethane 7 • Extruded Polystyrene 4.7 • Expanded Polystyrene 4 • Mineral Fiber 3.6 • Cellular Glass 3.4
R-7.4 6" Fiberglass Insulated Wall R-21 3" Insulated Metal Panel
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Presentation Notes
3. IMP Performance Testing and Design Benefits Panel Selection and Thermal Efficiency The primary variable in the selection of an insulated panel is the thickness needed to meet the required thermal value. After the thermal value is determined, a review of the structural span tables is necessary to ensure that the panels in the thickness selected will meet the structural requirements. IMP products offer nearly 2 ½ times the insulation efficiency as a field-assembled glass fiber system. To achieve an R-value of 20 with an insulated metal panel, you only need a 2 ¾" to 3" thickness. For the same R-20 using glass fiber along with a separate liner, sub girt and fascia, the wall system must be approximately 7.5" thick. When compared to conventional field-assembled walls, insulated metal panel walls yield a significant increase in a building’s useable floor space. R-Value Comparison A comparison of the insulating value for various insulation materials reveals urethane panels are the best insulators and experience virtually no measurable deterioration of thermal value, because the foam is covered by impermeable facers. Polystyrene has the disadvantage of being highly combustible and has about half the insulating value of polyurethane or polyisocyanurate. Mineral fiber and cellular glass provide less than half the insulating value per inch of thickness and are ineffective insulators when they become wet. For 1" of material: Polyurethane≥ 7 Extruded Polystyrene5 Expanded Polystyrene4 Mineral Fiber3.6 Cellular Glass3.4
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Ratings: Thermal Transmittance
• IMPs have a foam core that provides R-values generally ranging from 15 to 48 as tested with ASTM C 1363 at 75°F, in thicknesses from 2" to 6" for wall systems, and R-values ranging from 10 to 48 for roof systems
• Thermal values should be specified based on local codes, usage, and occupancy
5'-0" O.C. Typical
Thermal Deflection
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Presentation Notes
3. IMP Performance Testing and Design Benefits Thermal Effects All IMPs must demonstrate the ability to withstand exposure to temperature extremes on both the exterior and interior skins. Thermal expansion of insulated panels is accommodated by thermal bow. Because IMPs are a composite sandwich with both interior and exterior elements chemically bonded to the core, there can be no significant differential expansion between the interior and exterior elements. The insulated panels are positively fastened to purlins and girts, and the expansion of the panel is equally divided among the individual spans as thermal bow rather than linear expansion. The overall panel does not significantly elongate or contract; therefore, there is no need for slotted clips. Since thermal bow must be accounted for in all structural calculations for the panels, it does not adversely affect the performance of the panels. Ratings: Thermal Transmittance IMPs have a foam core that provides R-values generally ranging from 15 to 48 as tested with ASTM C 1363 at 75°F, in thicknesses from 2" to 6" for wall systems, and R-values ranging from 10 to 48 for roof systems. A 40°F mean test temperature is commonly used for refrigerated buildings. The test specimen, a completed panel assembly including side joints, is tested to account for any thermal inefficiency that may occur. Most products, though, perform very well because the side joints of virtually all panel designs have a natural thermal break between the outer and inner metal facers. Thermal values should be specified based on local codes, usage, and occupancy.
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Ratings: Foam Core Properties
Panel production must formulate a foam system with the right balance of the following properties: • density • shear strength • tensile strength • compressive strength • humid aging • heat and cold aging • flash and ignition properties
Presenter
Presentation Notes
3. IMP Performance Testing and Design Benefits Ratings: Foam Core Properties Foam cores are subjected to a series of physical performance tests to determine the strength and aging characteristics of the material. Foam is measured for (1) density, (2) shear strength, (3) tensile strength, (4) compressive strength, (5) humid aging, (6) heat and cold aging and (7) flash and ignition properties. The core properties of insulated metal panels will vary slightly with the type of foam that each manufacturer uses. The most critical factor in panel production is formulating a foam system with the right balance of these properties that will ensure structural integrity and adhesion of the foam to the metal faces.
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Ratings: Water Penetration and Air Infiltration
Complete panel assembly, mounted vertically with panel side joints: • ASTM E 331 - no uncontrolled water leakage at 6.24 psf air pressure
differential for wall panel assemblies • ASTM E 1646 - no uncontrolled water leakage through the panel joints at a
static pressure of 12 psf for roof panel assemblies
• Air infiltration should not exceed 0.06 cfm/sf at 6.24 psf air
pressure differential for wall panel assemblies, and in accordance with ASTM E 1680 at a static pressure of 12 psf for roof panel assemblies
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Presentation Notes
3. IMP Performance Testing and Design Benefits Ratings: Water Penetration and Air Infiltration A complete panel assembly mounted vertically containing panel side joints should be tested in accordance with ASTM E 331 with no uncontrolled water leakage at 6.24 psf air pressure differential for wall panel assemblies, and in accordance with ASTM E 1646 with no uncontrolled water leakage through the panel joints at a static pressure of 12 psf for roof panel assemblies. A complete panel assembly containing at least one principal panel side joint should be tested in accordance with ASTM E 283. Air infiltration should not exceed 0.06 cfm/sf at 6.24 psf air pressure differential for wall panel assemblies, and in accordance with ASTM E 1680 at a static pressure of 12 psf for roof panel assemblies.
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Ratings: Structural
• Structural load capacity should be verified by representative structural tests for positive as well as negative wind loads
• IMP manufacturer should provide calculations verifying the testing to ensure the structural capacity of the panels meet the project requirements
• Insulated metal roof panels should be tested to determine load capabilities by an independent testing agency • UL Wind Uplift–UL 580 or Factory Mutual Class 1 Rating for roof and
ceiling–FM 4471 • FM 1-60 and1-90 Windstorm Classifications or UL-60 and UL-90
classifications
Presenter
Presentation Notes
3. IMP Performance Testing and Design Benefits Ratings: Structural Structural load capacity should be verified by representative structural tests for positive as well as negative wind loads as outlined in ASTM E 72 for walls and roofs. The maximum deflection criterion for the insulated panels is typically L/180 for walls and L/240 for roofs. The effects of snow load and long-term loads on roof panels should be considered as appropriate in the structural analysis. The IMP manufacturer should provide calculations verifying that all factors affecting the load carrying capacity of the panels have been analyzed and verified by testing, and that the structural capacity of the panels meets the project requirements. Wind uplift effect on connections often controls span capability. Insulated metal roof panels should be tested to determine load capabilities by an independent testing agency, such as Underwriters Laboratories or Factory Mutual, and carry ratings similar to the following: UL Wind Uplift–UL 580 or Factory Mutual Class 1 Rating for roof and ceiling–FM 4471 If required by project conditions, insulated metal roof panels should carry either FM 1-60 and1-90 Windstorm Classifications or UL-60 and UL-90 classifications.
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Ratings: Fire
• IMPs should be tested by Underwriters Laboratories, Factory Mutual or similar testing and listing agencies for conformance with the requirements of the model building codes
• FM 4880 and FM 4881 - the foam core should have a maximum Flame Spread of 25 and a maximum Smoke Developed rating of 450
Presenter
Presentation Notes
3. IMP Performance Testing and Design Benefits Ratings: Fire To conform to the requirements of the major building codes, insulated metal panels should be tested by Underwriters Laboratories, Factory Mutual or similar testing and listing agencies for conformance with the requirements of the model building codes. In accordance with FM 4880 and FM 4881, the foam core should have a maximum Flame Spread of 25* and a maximum Smoke Developed rating of 450*. FM 4471 determines the potential for fire above the roof panels to meet Class 1A fire requirements. (*These numerical Flame Spread and Smoke Density indexes do not define the hazard presented by this or any other material under actual fire conditions.)
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Ratings: Coatings
• Color Change (ASTM D 2244) • Chalk Resistance (ASTM D 4214) • Specular Gloss at 60° (ASTM D 523) • Dew Cycle Weatherometer Test (ASTM D 366) • Humidity Resistance (ASTM D 2247) • Salt Spray Resistance (ASTM B 117) • T-Bend (ASTM D 4145) • Impact Resistance Test, Reverse Impact (ASTM D 2794) • Abrasion Resistance Test, Falling Sand (ASTM D 968) • Pencil Hardness HB to 2H (ASTM D 3363) • Cross Hatch Adhesion (ASTM D 3359)
Presenter
Presentation Notes
3. IMP Performance Testing and Design Benefits Ratings: Coatings Coatings are tested for, and in accordance with, the following: Color Change (ASTM D 2244) Chalk Resistance (ASTM D 4214) Specular Gloss at 60° (ASTM D 523) Dew Cycle Weatherometer Test (ASTM D 366) Humidity Resistance (ASTM D 2247) Salt Spray Resistance (ASTM B 117) T-Bend (ASTM D 4145) Impact Resistance Test, Reverse Impact (ASTM D 2794) Abrasion Resistance Test, Falling Sand (ASTM D 968) Pencil Hardness HB to 2H (ASTM D 3363) Cross Hatch Adhesion (ASTM D 3359)
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Design Benefits: Installation
Field Assembled
Factory Assembled
1. Liner Panel or Deck 2. Vapor Retarder 3. Insulation Board 4. Standing Seam Roof Panel or Membrane/Ballast
Insulated Metal Roof Panel: Single Element
Presenter
Presentation Notes
3. IMP Performance Testing and Design Benefits Design Benefits: Installation Roof Panels: Factory- vs. Field-Assembled All-in-one composite roof panels provide faster one-step installation and reduce erection labor time and costs. With a one-piece panel, there is no potential for misapplication of the vapor barrier/retarder, which may occur with field built-up metal roof systems or single-ply membranes. Foam metal roof panels have consistent insulating values across the entire roof area. There are no compressed insulation points like with blanket insulation, which is draped over the purlins. The side joints of the panel have a continuous thermal break to eliminate the conductance of either heat or cold. The panels are resistant to damage caused by normal foot traffic; have minimal potential for oil canning; can span greater distances; and can withstand heavier positive loads than field-assembled metal roof systems. Panels may be installed in more adverse weather conditions and provide an erection platform from which to work as the installation progresses.
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Design Benefits: Building Installation Efficiency
• Panels are lightweight and less affected by weather conditions
• One-piece construction process; factory-fabricated IMPs are attached directly to the supporting structure
• Reduced construction and interim financing costs
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3. IMP Performance Testing and Design Benefits Design Benefits: Building Installation Efficiency On large commercial and industrial facilities, such as cold storage facilities, hangars, manufacturing plants, food processing facilities, office buildings and convention centers, insulated metal wall systems are installed very quickly. Installation efficiency with IMPs is higher than with other field-assembled products, because they are lightweight and less affected by weather conditions. The one-piece construction process assures rapid completion of the wall and roof system. Factory-fabricated IMPs are attached directly to the supporting structure, and the traditional multiple steps to construct the insulated wall and roof are eliminated. Faster building completion means reduced construction and interim financing costs. Installation speed is the key to many projects today. Depending on job complexity and size, insulated metal wall panels can be installed at a rate of up to 5,000 sq. ft. per 8-hour shift by a four-man crew, and up to 10,000 sq. ft. per 8-hour shift by a five-man crew and crane on an insulated metal roof panel project. Higher installation rates can be achieved with insulated metal roof panels. On large building projects, under normal wind conditions, support girt spacing in the 8' to 10' range is used to take advantage of the high panel strength. Also, 24 and 26 light- gauge metal skins are used with profiled or striated patterns to minimize the material cost while maintaining the structural integrity and product flatness.
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Design Benefits: Flexibility and Aesthetics
• Available in a wide range of colors, finishes, and textures
• Flat, profiled, curved and formed panels may be installed either horizontally or vertically
• Flush appearance when panels are attached with concealed clips and fasteners in the side joint
• Custom widths and specialty features to suit project needs
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3. IMP Performance Testing and Design Benefits Design Benefits: Flexibility and Aesthetics Architecturally, IMPs offer design flexibility. They are available in a wide range of colors, in a wide range of finishes and textures to suit any application or environment. Flat, profiled, curved and formed panels may be installed either horizontally or vertically for maximum design impact. Attached with concealed clips and fasteners in the side joint, architectural wall panels provide a beautiful flush appearance. Custom widths and varying side joint reveals for horizontally applied panels are available. Other specialty features that can be incorporated into the wall include curved and radius panels and integrated windows for unlimited variations and dramatic building designs.
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Design Benefits: Panel Profiles
The bold vertical lines of a fluted wall panel with a ribbed profile enhance the high-tech industrial look.
A lightly corrugated profile on both faces of the panel ensures symmetry from outside the building to inside, and from room to room in interior partition applications.
The striated wall panel is an attractive alternative to typical flat wall panels. The exterior face exhibits a virtual flat appearance from a short distance away.
Vertical and horizontal application Factory-folded panel ends Preformed corners Modules: 30", 36", 42" Thickness: 2", 2 ½", 3" Lengths: 8' to 40' for 30" & 36" modules, and 8' to 32' for 42"
Vertical and horizontal application Factory-folded panel ends Textured brake form trim Modules: 36", 42" Thickness: 2", 2 ½", 3" Lengths: 8' to 40'
A flat exterior profile with a heavy non-directional embossed stucco texture provides the look of a masonry stucco finish.
A ribbed wall panel is ideal for interior partition walls, exterior walls and soffit applications where a light vertical accent line is desired.
• LEED credit requirements cover the performance of materials
in aggregate, not the performance of individual products
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4. Environmental Considerations and Green Rating Systems U.S. Green Building Council IMPs are green construction products which meet the requirements of many rating, certification and labeling programs. This section of the presentation analyzes the sustainability benefits, attributes and performance criteria of IMPs relative to qualifying for credits within the U.S. Green Building Council’s LEED® green building certification program. The U.S. Green Building Council (USGBC) is a 501(c)(3) non-profit organization composed of leaders from every sector of the building industry working to promote buildings and communities that are environmentally responsible, profitable and healthy places to live and work. USGBC developed the LEED (Leadership in Energy and Environmental Design) green building certification program, the nationally accepted benchmark for the design, construction, and operation of high-performance green buildings. For detailed information about the council, their principles and programs, please visit www.usgbc.org. LEED® Green Building Certification Program The LEED® green building certification program is a point-based system where points are awarded for actions taken during design, construction, and use phases to reduce the impact a project and its construction will have on the environment and natural resources. The program has five main categories (Sustainable Sites (SS), Water Efficiency (WE), Energy & Atmosphere (EA), Materials & Resources (MR), and Indoor Environmental Quality (IEQ)), and two additional categories (Innovation & Design Process and Regional Priority) for actions not specifically addressed in the five main categories. LEED credit requirements cover the performance of materials in aggregate, not the performance of individual products or brands. Therefore, products that meet the LEED performance criteria can only contribute toward earning points needed for LEED certification; they cannot earn points individually toward LEED certification.
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LEED Credits
IMPs may help a building project satisfy the requirements of earning LEED credits in the following categories:
• SS Credit 7.2: Heat Island Effect: Roof
• MR Credit 1.1: Building Reuse: Maintain Existing Walls,
Floors and Roof • MR Credit 1.2: Building Reuse: Maintain Interior Non-
4. Environmental Considerations and Green Rating Systems LEED Credits Consult individual manufacturers for specific information about LEED programs and relevant credits, but as listed here and on the following slides, IMPs may help a building project satisfy the requirements of earning LEED credits in the following categories: SS Credit 7.2: Heat Island Effect: Roof IMP color coated roof panels for steep-sloped roof applications and white for low-sloped roof applications meet or exceed the Solar Reflectance Index (SRI) requirements—an SRI greater than or equal to 78 for low-sloped roof applications and 29 for steep-sloped roof applications, used on at least 75% of the roof’s surface. MR Credit 1.1: Building Reuse: Maintain Existing Walls, Floors and Roof Insulated metal wall panels used in an existing building envelope or structure can be disassembled, moved, and reused for the envelope/structure of a new project, contributing to points for maintaining at least 55% of the surface area of existing building structure and envelope. MR Credit 1.2: Building Reuse: Maintain Interior Non-Structural Elements IMPs used in a building’s interior can be disassembled, moved, and reused for the interior of a new project, contributing to points for using existing interior non-structural elements in at least 50% (by area) of the completed building. MR Credit 3: Materials Reuse IMPs, both interior and exterior, can be disassembled, moved, and reused for a new project, contributing to points for using salvaged, refurbished or reused materials such that the sum of these materials constitutes at least 5% (based on cost) of the total value of materials on the project. MR Credit 4: Recycled Content The percentages of recycled content in IMPs (as outlined on slide 18) contribute to using materials with recycled content such that the sum of post-consumer recycled content plus one-half of the pre-consumer content constitutes at least 10% (based on cost) of the total value of the materials in the project. MR Credit 6: Rapidly Renewable Materials The foam core in IMPs contains a component that contributes to this credit —the component in some IMPs is sucrose from sugar beets, used to replace petroleum-based products. Requires using rapidly renewable building materials and products (made from plants that are typically harvested within a ten-year cycle or shorter) for 2.5% of the total value of all building materials and products used in the project (based on cost).
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LEED Credits
• EA Prerequisite 2: Minimum Energy Performance (Required) • EA Credit 1: Optimize Energy Performance • EA Credit 2: On-Site Renewable Energy
• WE Credit 1: Water Efficient Landscaping • WE Credit 2: Innovative Wastewater Technologies • WE Credit 3: Water Use Reduction • ID Credits 1.1 to 1.4: Innovation in Design
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4. Environmental Considerations and Green Rating Systems LEED Credits EA Prerequisite 2: Minimum Energy Performance (Required) IMPs will contribute to higher energy efficiency of a building that must comply with a 10% improvement in the performance compared to benchmark rating based on ASHRAE/IESNA Standard 90.1-2007 (with errata but without addenda). EA Credit 1: Optimize Energy Performance IMPs are independently tested using the ASTM C 1363 Hot Box method for thermal transmittance. The results meet or surpass the minimums outlined in the ASHRAE/IESNA Standard 90.1-2007. Using IMPs will considerably contribute to points for the building demonstrating a percentage improvement in the proposed building performance rating compared to the baseline performance rating by a whole building project. EA Credit 2: On-Site Renewable Energy The use of IMP solar roof panels creates a source of on-site renewable energy that will offset a portion of a building’s energy cost. The energy produced by the renewable system must be expressed as a percentage of the building’s annual energy cost calculated using the ASHRAE/IESNA Standard 90.1-2007 or the U.S. Department of Energy’s Commercial Buildings Energy Consumption Survey database. IEQ Credit 4.1: Low Emitting Materials: Adhesives & Sealants All adhesives and sealants must comply with the standards of the South Coast Air Quality Management District, Rule #1168. For architectural sealants, the VOC maximum limit is 250 grams/liter. The sealants supplied with IMPs have VOC contents below the maximum limit, contributing to one point for all adhesives and sealants used on the interior of the building complying with stated standards. IEQ Credit 8.1: Daylight & Views: Daylight The use of the fully integrated window system with horizontal IMPs can significantly contribute to points for demonstrating that a minimum daylight illumination level of 25 foot-candles has been achieved in a minimum of 75% of the regularly occupied area. WE Credit 1: Water Efficient Landscaping IMPs integrated into a building’s rainwater harvesting system can contribute a point for reducing potable water consumption for irrigation by 50% from a calculated mid-summer baseline case or using captured rainwater for non-potable uses for irrigation. WE Credit 2: Innovative Wastewater Technologies IMPs integrated into a building’s rainwater harvesting system can help to reduce potable water used for building sewage conveyance by 50%. WE Credit 3: Water Use Reduction IMPs integrated into a building’s rainwater harvesting system can contribute to points for employing a strategy that in aggregate uses at least 20% less water than the water use baseline calculated for the building (not including irrigation) after meeting the Energy Policy Act of 1992 fixture performance requirements. ID Credits 1.1 to 1.4: Innovation in Design IMPs integrated into a building’s overall design can contribute to points if the building’s design team applies strategies or measures that demonstrate performance above the requirements in categories and/or innovative performance not specifically addressed by LEED in ID Credits 1.1 to 1.4.
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Pacific Plaza, LEED Platinum
• More than 26,000 sq. ft. of IMPs were used to clad the inhabited portion of the office building/parking garage structure
• 3" panels finished in Weathered Zinc and installed horizontally
in 24", 30" and 36" widths • IMPs interface with a cement composite façade system used to
clad the exterior walls on parking garage portion of the building
Pacific Plaza, LEED Platinum
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5. LEED® Case Studies Pacific Plaza, LEED Platinum The Pacific Plaza building in downtown Tacoma, WA was once a four-story, decades-old and crumbling parking garage. Now, the striking new six-story structure is state-of-the-art and Washington’s only LEED Platinum core and shell construction project. The $35 million, 250,000 sq. ft. project features two new floors of 68,800 sq. ft. Class A commercial space; 32,000 sq. ft. of refurbished storefront office and retail space; and a 28,000 sq. ft. green roof. More than 26,000 sq. ft. of IMPs were used to clad the inhabited portion of the office building/parking garage structure. The 3" panels were finished in Weathered Zinc and installed horizontally in 24", 30" and 36" widths. The IMPs interface with a cement composite façade system used to clad the exterior walls on the parking garage portion of the building. Pacific Plaza is the result of a successful public-private partnership between the City of Tacoma and the local development team of Pacific Plaza Development, LLC. The City replaced a seismically deficient garage with a larger, like-new facility, while the developer obtained street front retail space and air rights for commercial space without the burden of providing structure parking. The result has rejuvenated a key commercial district.
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Hope Lake Lodge, LEED Silver
• Approx. 60,000 sq. ft. of IMPs were used to clad the roof and walls of the Varco Pruden building
• Kynar finish on 4" thick roof panels and 3" thick wall panels • Steel structure enabled use of large clear spans of IMPs
to house the water park features • Temperature inside is maintained at 80-84°F year-round
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5. LEED® Case Studies Hope Lake Lodge, LEED Silver The addition of a modern indoor water park at Hope Lake Lodge at the Greek Peak Ski Center in central New York has transformed the existing resort into a year-round destination. The temperature inside the 28,000 sq. ft. facility is maintained at 80-84 degrees even during the most frigid months. . The 4" thick roof panels were finished in a forest green on the exterior and white on the interior. The 3" thick wall panels were finished in a terra cotta color on the exterior and beige on the interior. The use of a steel super-structure with insulated metal wall and roof panels allowed the design team to create large clear spans necessary for housing the water park features and to provide high thermal efficiency. Dealing with the inherent high humidity and chlorine-laden atmosphere was an issue, so the steel members were galvanized and then powder-coated to resist corrosion. The IMPs utilize a Kynar finish. The IMPs were also used to clad an adjoining 7,000 sq. ft. arcade that links the water park to the Hope Lake Lodge and Conference Center.
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Ballard Blocks, LEED Silver
• Approx. 51,000 sq. ft. of IMPs were utilized
• 2" panels in a custom color and were installed horizontally
• IMPs provided all of the systems—the metal skin, insulation and vapor barrier—in one product
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5. LEED® Case Studies Ballard Blocks, LEED Silver The new Ballard Blocks development in the Ballard area of Seattle offers 366,000 sq. ft. of commercial and retail space in two buildings connected by a pedestrian promenade and below-grade parking level. The objective was to have a clean, modern design that met sustainable building goals as well as a high-performance building both in terms of the systems and the materials. Approximately 51,000 sq. ft. of IMPs were utilized. The 2" panels were finished in custom color and were installed horizontally. The IMPs provided all of the systems—the metal skin, insulation and vapor barrier—in one product. Sustainable design elements include a high-efficiency HVAC system, low-VOC construction products, preferred parking for fuel-efficient vehicles, and native and drought-tolerant plant species which enable the project to avoid installation of a costly irrigation system as well as brownfield site remediation. Throughout construction, contractors diverted more than 93% of demolition and construction waste from landfills. The project is registered as LEED Silver and is in the process of being certified.
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Aerzen USA, LEED Gold
• Approx. 54,000 sq. ft. of IMPs were used on the walls and roof
• Lightly corrugated panel profile on both faces ensures symmetry from outside the building to inside, and from room to room in partition applications
• IMPs normally used for freezer applications quadrupled the insulation value
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5. LEED® Case Studies Aerzen USA, LEED Gold The new Aerzen USA plant in Coatesville, PA manufactures high-end industrial blowers, vacuum pumps and compressors. Approximately 54,000 sq. ft. of IMPs were used in wall and roof applications. The 5" wall panels were finished in Kynar 500 finish on the exterior, and the 5" standing seam roof panels were finished in Kynar 500 white on the exterior. The interior lightly corrugated panel profile for both the roof and walls is corrugated on both faces to ensure symmetry from outside the building to inside and from room to room in partition applications. The IMPs became a part of the project approximately one year after the design process started, since the design team was looking for a cost- effective way to provide a really smart manner of finishing and insulating the space. The IMPs provided the required insulation qualities, met budget constraints and were easy to install. The building was closed in less than a week. The IMPs normally used for freezer applications quadrupled the insulation value. An added benefit of the all-in-one composite panels is that they installed directly on top of the purlins, and provide an interior skin that is attractive without having to add a liner panel of any sort.
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Summary and Resources
Project: Takao America
Project: Swiss American
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6. Summary and Resources Course Summary IMPs are rigid urethane foam sandwiched between two sheets of coated metal. They are composite, single-step, factory-insulated, energy-saving panel systems available in a variety of styles and sizes depending on application. IMPs can be flat or come with various profiles, and can be installed horizontally or vertically. IMPs provide insulating values across the entire wall and roof area, and the impermeable faces and built-in thermal breaks ensure high insulating values for the life of a building. The one-piece construction process means rapid completion of the wall and roof system, and the panels are lightweight yet structurally strong enough for long spans. Class I polyurethane foam meets the requirements of the major model building codes; and, concealed attachment offers a clean, high-profile appearance. IMPs offer the sustainability benefits, attributes and performance criteria required to meet today’s green building standards, including the U.S. Green Building Council’s LEED® green building certification program. Resources Metl-Span, www.metlspan.com Metal Construction Association, www.metalconstruction.org U.S. Green Building Council, www.usgbc.org The Metal Initiative, www.themetalinitiative.com Cool Roof Rating Council, www.coolroofs.org
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Course Evaluations
In order to maintain high-quality learning experiences, please access the evaluation for this course by logging into CES Discovery and clicking on the Course Evaluation link on the left side of the page.
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Course Evaluations In order to maintain high-quality learning experiences, please access the evaluation for this course by logging into CES Discovery and clicking on the Course Evaluation link on the left side of the page.
Questions? This concludes The American Institute of Architects Continuing Education Systems Course
www.mbci.com
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Conclusion Thank you for your time Questions? This concludes The American Institute of Architects Continuing Education Systems Course Closing remarks……
