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Abstract

This final report summarizes the work conducted by the Building America Industrialized Housing Partnership (www.baihp.org) for the period 9/1/99 – 6/30/06. BAIHP is led by the Florida Solar Energy Center of the University of Central Florida and focuses on factory built housing. In partnership with over 50 factory and site builders, work was performed in two main areas – research and technical assistance.

In the research area -- through site visits in over 75 problem homes, we discovered the prime causes of moisture problems in some manufactured homes and our industry partners adopted our solutions to nearly eliminate this vexing problem. Through testing conducted in over two dozen housing factories of six factory builders we documented the value of leak free duct design and construction which was embraced by our industry partners and implemented in all the thousands of homes they built. Through laboratory test facilities and measurements in real homes we documented the merits of “cool roof” technologies and developed an innovative night sky radiative cooling concept currently being tested. We patented an energy efficient condenser fan design, documented energy efficient home retrofit strategies after hurricane damage, developed improved specifications for federal procurement for future temporary housing, compared the Building America benchmark to HERS Index and IECC 2006, developed a toolkit for improving the accuracy and speed of benchmark calculations, monitored the field performance of over a dozen prototype homes and initiated research on the effectiveness of occupancy feedback in reducing household energy use.

In the technical assistance area we provided systems engineering analysis, conducted training, testing and commissioning that have resulted in over 128,000 factory built and over 5,000 site built homes which are saving their owners over $17,000,000 annually in energy bills. These include homes built by Palm Harbor Homes, Fleetwood, Southern Energy Homes, Cavalier and the manufacturers participating in the Northwest Energy Efficient Manufactured Home program. We worked with over two dozen Habitat for Humanity affiliates and helped them build over 700 Energy Star or near Energy Star homes. We have provided technical assistance to several show homes constructed for the International builders show in Orlando, FL and assisted with other prototype homes in cold climates that save 40% over the benchmark reference. In the Gainesville Fl area we have several builders that are consistently producing 15 to 30 homes per month in several subdivisions that meet the 30% benchmark savings goal. We have contributed to the 2006 DOE Joule goals by providing two community case studies meeting the 30% benchmark goal in marine climates.

Acknowledgment

This work is sponsored, in large part, by the US Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, Building Technologies Program under cooperative agreement number DE-FC26--99GO10478. This support does not constitute an endorsement by DOE of the views expressed in this report. Additional funding was provided by the Florida Department of Community Affairs and the Northwest Energy Efficiency Alliance. Their support is appreciated.

The authors appreciate the encouragement and support from George James, Ed Pollock, and Chris Early, program personnel at DOE, Keith Bennett, project officer in Golden, Colorado and Bill Haslebacher, project officer at the National Energy Technology Laboratory. We also are grateful to our colleagues Philip Fairey, and Safvat Kalaghchy for advice and assistance. Thanks to project staff (Bob Abernethy, Mable Flumm, Wanda Dutton, Rafik Alidina and Joy Mayne) and students (Matt Lombardi, Mike McCloud, Matt McCloud, Josh Newland, and Jamie Cummings) for their contributions

This work could not have been completed without the active cooperation of our industry partners and all collaborators. We greatly appreciate their support.

Table of Contents

Executive Summary

I. BAIHP Introduction

II. BAIHP Technical Assistance

All America Homes of Gainesville AMJ Construction Applegren Construction, Eastern Dakota Housing Alliance (EDHA) Atlantic Design and Construction Avis American Homes Bellview Air Bobek Building Systems Cambridge Homes Cardinal Homes, Inc. Castle and Cooke Champion Homes, See Also “Fort Lewis Base Housing” City of Gainesville – Cedar Grove II City of Orlando, The Orlando House City of Lubbock Community Development Clayton Homes Dukane Precast Dr Horton Dye Company and DelAir – Southern Living Home East Bay Development (Formerly Midgard Associates) Energy Structures & Systems, Inc. EnergyGauge® Fleetwood Homes Fort Lewis Military Housing, Champion Homes, Equity Residential GreenStone Industries Florida International University, 2005 Solar Decathlon G.W. Robinson Builder/Developer Florida Green Building Coalition Habitat For Humanity – BAIHP Partnership Heat Pipe Technology HKW Enterprises Homark Homes Homes of Merit 2005 International Builders Show Showhomes (6th Budget Period)      A. New American Home, Built by Goehring Morgan Construction      B. Discovery Custom Homes Modular Showhome      C. Not So Big Showhouse 2006 International Builders Show Showhomes      The 2006 International Builders Show Showhomes was held in Orlando, Florida in January. BAIHP      staff worked in the Building America booth and provided technical assistance to several IBS show      homes      A. New American Home      B. Palm Harbor Homes 2007 International Builders Show      A. Palm Harbor Modular Show Homes      B. New American Home Kashi Church Foundation Kit HomeBuilders West Marlette Homes, Kokanee Creek Marlette Homes, NOGI Gardens Miami-Dade Hope VI Project Midgard Associates (See East Bay Development) Nez Perce Fish Facility New Generation Homes Northwest Energy Efficient Manufactured Housing Program (NEEM) Oakwood Homes Palm Harbor Homes Patrick Family Housing, LLC Penn Lyon Homes Podia Construx/Rainbow Springs Construction Royal Concrete Concepts Sandspur Housing Scott Homes Southern Energy Homes Spain Construction Stylecrest Sales (Coleman HVAC Systems) Timeless Construction Tommy Williams Homes (On) Top of the World Retirement Community Trinity Construction Corporation Vincent Village WCI Communities, Inc.

III. BAIHP Research

BAIHP Research Overview

A. Manufactured Housing Research Building Science and Moisture Problems in Manufactured Housing – Background BAIHP Field Visits to Problem Manufactured Homes Manufacturers Participating in Building Science Research (including activity with individual      manufacturers) Side By Side Study Of Energy Use And Moisture Control Comparing Standard Split System Air      Conditioning And A Coleman® Prototype Heat Pump, Bossier City, LA WSU Energy House Zero Energy Manufactured Home (ZEMH) Manufactured Housing Indoor Air Quality Study Manufactured Housing Laboratory – Ventilation Studies Side by Side Manufactured Housing Energy Use Study, North Carolina A&T Portable Classrooms Duct Testing Data from Manufactured Housing Factory Visits Crawl Space Moisture Research for HUD Code Homes Recommendations for FEMA Ruggedized Manufactured Home for Temporary Housing Comboflair Integrated HVAC System

B. Site Built Housing Research Building America Prototype, Cambridge Homes Unvented Attic Study, Rey Homes Sharpless Construction, Hoak Residence Energy and Moisture Studies Zero Energy Affordable Housing, ORNL and Loudon County Habitat for Humanity Apartment Ventilation and Humidity Study with Sandspur Housing Federation of American Scientists’ Rasbach Provident Home Radiant Floor Heating Research Hurricane Water Intrusion Research Hurricane Retrofit Research

C. Field and Laboratory Building Science Research Air Handler Air Tightness Study Air Conditioning Condenser Fan Efficiency Fenestration Research Reflective Roofing Research Return Air Pathway Study Heat Pump Water Heater Evaluation NightCool - Building Integrated Cooling System Plug Load Reduction Study Solar Integrated Roofing Panels Hot Water Distribution Systems Research Building America Benchmark Toolkit for Programmers Comparison of Current Building Energy Analysis Standards for Building America, Home Energy      Ratings and the 2006 International Energy Conservation Code Cooling Performance Assessment of Building America Homes

IV. BAIHP Web Page, Training Presentations and Publications

BAIHP Web Site BAIHP Training and Presentations BAIHP Publications List - All Budget Periods (09/99 - 06/06)

V. BAIHP Collaborations

VI. BAIHP Project Management