FREQUENTLY ASKED QUESTIONS
What are ICS Eco-Sips?
SIPs stands for Structural Insulated Panels. When installed, a SIP provides both structure (support strength) and insulation (resistance to the transfer of heat, cold, sound, vibration, etc.). SIPs designed and manufactured by Insulated Component Structures (ICS) provide the best thermal/structural envelope available today. While most commonly used for exterior walls, SIPs can also serve as a load-bearing floor and ceiling/roof. ICS SIPs are designed to carry the entire range of structural loads in a building. ICS panels are manufactured by injecting polyurethane foam between two surfaces. As part of each panel, structural elements add tremendous strength. These panels are joined together via a patented panel connection system featuring embedded steel cam-locks and a double tongue-and-groove interface, ensuring a sealed, tight fit. A typical lCS 4-1/2 inch (11.43 centimeters) thick panel has an R-value of R-28 or higher (compared to the claim of R-13 for fiberglass insulation). A 6-1/2" (16.51 centimeters) thick panel has an R-value of R-42 or higher (compared to the claim of R-19 for fiberglass insulation). The outer surfaces (also called “skins”) can be oriented strand board (OSB), fiber-cement (FC), galvanized stainless steel (GSS), fiber-reinforced plastic (FRP), various sidings, or other structural materials. Standard drywall can also be used as a “skin,” but does not qualify as a structural support element.
Why are ICS Eco-SIPs so much better?
ICS SIPs save time, money, and energy. They outperform other building methods in virtually every aspect because of the structural strength, ease of erection, and insulation value of the components.
When someone says "R-value", what they are talking about is resistance to conductive heat flow in a given medium, such as fiberglass insulation. The higher the number, the greater the resistance to conduction of heat. Thus, a product with a value of R-28 is much better than a product with a value of R-13. However, R-value is only a measure of conduction, and does not measure the other five mechanisms of heat transfer. Insulations that allow airflow cannot compare to ICS SIPs.
In reality, this reasoning doesn't take into account all the other components that go into making a wall: wood or steel studs every 16 or 24 inches reduce the overall R-value, and allow airflow within the wall space. In addition, other construction materials and components, such as bracing, nails or screws, wiring and switch boxes, and any number of things that are not insulation, and, in all likelihood, have low R-values, negatively affect the overall quality of an insulated wall, floor, or ceiling. Poor installation of fiberglass batt insulation can also reduce the R-effect significantly. A wall with fiberglass insulation rated at R-13 can have an actual result of R-8 or less due to these other factors.
A study by the Oak Ridge National Labs (ORNL) in Tennessee proves that a 4" SIP wall outperforms traditional 2" x 4" stick and batt construction, and even edges out 2" x 6" construction in terms of thermal performance. SIPs (if made with structural “skins” such as OSB) are structural elements. There are no studs or braces to cause breaks in the insulative action. The end result is a more comfortable, energy-efficient building that performs up to specifications in real-world conditions. Unlike stick and batt construction, which can be subjected to poorly installed - even missing - insulation; the nature of the ICS SIP is such that the structural and insulative elements are joined and bonded together as one. There are no hidden gaps. A solid layer of foam insulation is integral to panel construction.
The ORNL study found that SIPs perform at approximately 97% of their stated R-value overall, losing only 3% to nail holes, seams, splines and the like. Wiring chases are preformed into the foam core, providing a continuous layer of insulation keeping the elements out and the interior free of drafts and cold spots. ICS SIPs are superior to traditional, old-fashioned methods of building construction.
When someone says "R-value", what they are talking about is resistance to conductive heat flow in a given medium, such as fiberglass insulation. The higher the number, the greater the resistance to conduction of heat. Thus, a product with a value of R-28 is much better than a product with a value of R-13. However, R-value is only a measure of conduction, and does not measure the other five mechanisms of heat transfer. Insulations that allow airflow cannot compare to ICS SIPs.
In reality, this reasoning doesn't take into account all the other components that go into making a wall: wood or steel studs every 16 or 24 inches reduce the overall R-value, and allow airflow within the wall space. In addition, other construction materials and components, such as bracing, nails or screws, wiring and switch boxes, and any number of things that are not insulation, and, in all likelihood, have low R-values, negatively affect the overall quality of an insulated wall, floor, or ceiling. Poor installation of fiberglass batt insulation can also reduce the R-effect significantly. A wall with fiberglass insulation rated at R-13 can have an actual result of R-8 or less due to these other factors.
A study by the Oak Ridge National Labs (ORNL) in Tennessee proves that a 4" SIP wall outperforms traditional 2" x 4" stick and batt construction, and even edges out 2" x 6" construction in terms of thermal performance. SIPs (if made with structural “skins” such as OSB) are structural elements. There are no studs or braces to cause breaks in the insulative action. The end result is a more comfortable, energy-efficient building that performs up to specifications in real-world conditions. Unlike stick and batt construction, which can be subjected to poorly installed - even missing - insulation; the nature of the ICS SIP is such that the structural and insulative elements are joined and bonded together as one. There are no hidden gaps. A solid layer of foam insulation is integral to panel construction.
The ORNL study found that SIPs perform at approximately 97% of their stated R-value overall, losing only 3% to nail holes, seams, splines and the like. Wiring chases are preformed into the foam core, providing a continuous layer of insulation keeping the elements out and the interior free of drafts and cold spots. ICS SIPs are superior to traditional, old-fashioned methods of building construction.
Why does ICS use polyurethane rather than polystyrene?
ICS chose to use polyurethane foam insulation instead of expanded polystyrene (EPS) for several reasons. First, polyurethane is a far better insulator. ICS polyurethane foam has a stable R-value of R-7 per inch of thickness, versus R-4 for EPS. This means that you can achieve R-28 with 4.5-inch walls. EPS-insulated walls would have to be nearly twice as thick to achieve the same R-value. Second, when polyurethane foam is injected into panels, the panels are stronger than EPS panels. While the EPS is simply glued onto the substrates, injected polyurethane foam adheres and bonds to every surface (substrates, top-plates, splines, cam-locks, electrical boxes, etc.), and then becomes rigid. Polyurethane panels can withstand higher compression (or axial), transverse (or flexural), and racking loads. Third, polyurethane has better fire, flame, and smoke characteristics. Polyurethane does not melt at any temperature. It will withstand constant service temperatures up to 180-degrees Fahrenheit and will not char up to 275-degrees Fahrenheit. Fourth, polyurethane allows the use of cam-locks, embedded into the foam. This saves labor in the field and makes strong panel connections. Cam-locks cannot be embedded into EPS. Simply put, polyurethane foam is a superior product for structural insulated panels.
Why are ICS Eco-SIPs stronger?
ICS SIPs are a structural composite acting like an I-beam. The skins act like the flanges and the rigid core is similar to the web. In short, the three components work together, rather than against one another. The composite assembly yields stiffness, strength, and predictable responses to loads. ICS SIPs have an integral double-tongue & groove system for joining panels together that also helps carry the structural load. SIPs resist both compressive forces from above and buckling and warping forces from the sides. ICS tests to the American Society of Testing and Materials (ASTM) E72-04 “Standard Test Methods of Conducting Strength Tests of Panels for Building Construction” for compression, transverse, and racking loads. Depending on the type of structural test being administered, SIPs range between two and seven times stronger than traditional framing.
Not only do test results show the panels are stronger, but real-life natural disasters have proven it. The great Hanshin (Kobe, Japan) and North Ridge earthquakes, Hurricane Andrew, a Colorado tornado, a Portland gas explosion, and an Omaha fire, have done more to prove SIP strength to homeowners, architects, and builders than all the scientific tests.
Not only do test results show the panels are stronger, but real-life natural disasters have proven it. The great Hanshin (Kobe, Japan) and North Ridge earthquakes, Hurricane Andrew, a Colorado tornado, a Portland gas explosion, and an Omaha fire, have done more to prove SIP strength to homeowners, architects, and builders than all the scientific tests.
Are the high efficiency claims valid?
Yes. Four key factors make the average SIP building very energy-efficient. First, polyurethane foam provides higher insulating value per inch than traditional fiberglass or cellulose insulation. Second, there is much less wood framing within the typical panel, which increases total R-value. Third, the foam is continuous and is not susceptible to the commonplace flaws found in average batt installations. Fourth, foam, when bonded directly to the exterior and interior wall “skins,” doesn't allow air infiltration around it.
SIP-made buildings are vastly more energy-efficient, stronger, quieter, and draft free than older building methods likes stud framing with fiberglass batt insulation. Fiberglass is sometimes used for furnace filters because air moves through so freely. Polyurethane foam consists of billions of tiny cells with solid polyurethane cellular walls. Air cannot flow from cell to cell or between cells. Rigid foam insulation is used as solid component insulation in almost every industry concerned about heat transfer, such as the refrigeration industry, for its inherent efficiency and prevention of air movement. These attributes are built right into the ICS SIPs panels. Less air movement or leakage translates into far fewer drafts, fewer penetrations of noise, much lower energy bills, and a significantly more comfortable and controllable indoor environment. You can have a quieter, more comfortable home and office.
SIP-made buildings are vastly more energy-efficient, stronger, quieter, and draft free than older building methods likes stud framing with fiberglass batt insulation. Fiberglass is sometimes used for furnace filters because air moves through so freely. Polyurethane foam consists of billions of tiny cells with solid polyurethane cellular walls. Air cannot flow from cell to cell or between cells. Rigid foam insulation is used as solid component insulation in almost every industry concerned about heat transfer, such as the refrigeration industry, for its inherent efficiency and prevention of air movement. These attributes are built right into the ICS SIPs panels. Less air movement or leakage translates into far fewer drafts, fewer penetrations of noise, much lower energy bills, and a significantly more comfortable and controllable indoor environment. You can have a quieter, more comfortable home and office.
Does the insulation lose R-Value over time?
No. ICS uses a polyurethane foam formulation that stabilizes at a relatively high R-value (about R-7 per inch of thickness) once it is placed in a building's wall, floor, or ceiling system. The R-value of a fully cured polyurethane panel is about two-and-half times higher than that of a fiberglass-insulated stud wall.
Are SIP homes too tight for good indoor health?
No. Research indicates that the best way to provide a building (such as a home or office) with good indoor air quality requires two essential steps. First, the building has to be built as tightly as practical; it is easier to control air movements in a tight home than in a leaky one. Second, the building must have modern, upgraded mechanical ventilation features in the HVAC system so that it provides an appropriate and steady flow of fresh air. These modern HVAC features also add energy-efficiency.
How do you wire SIP houses?
Wiring an ICS SIP building takes a little extra planning prior to construction. ICS places a conduit chase and electrical boxes in the foam according to the structure's plan and “blueprints.” Then, an electrician simply “fishes” the wire through the conduits to where the wire is needed. Wiring chases and boxes can be provided for electrical outlets and switches, wiring junctions, cable television outlets, telephone outlets, computer circuits, etc.
What about plumbing?
Plumbing is not usually placed in exterior walls, but rather through the floor into the bottom of cabinets. Where exterior wall vent-pipes are necessary, chases can be formed in the foam cores. Island or loop vents are also common practices and can be found in the plumbing codes.
How do you make the openings for doors and windows?
Doors and windows are identified in the building plan. As part of the ICS manufacturing process, door and window openings are framed and blocked out. When foam is injected into the panel, the door and window frames become an integral part of the panels.
What about SIPs in fires?
Fire requires three components: ignition, oxygen, and fuel. ICS SIPs have no "air" within the solid core of the insulation. The fire cannot "run up the wall" cavity, as is the case with traditional stud construction. Polyurethane foam does not melt. SIPs have passed every standard fire test that is required of wood-based or “Type V” construction. To the surprise of some building researchers, data from extensive laboratory fire testing as well as reports from actual house fires indicates that SIP structures tend to be more resistant to house fires than standard stud structures.
ICS tests their panels to the American Society for Testing and Materials (ASTM) E84-04 “Standard Test Method for Surface Burning Characteristics of Building Materials” for smoke spread and flame spread. The panels have a Class 1 foam core. The foam components are formulated to have a flame spread of less than 25 units and smoke spread of less than 400 units.
ICS tests their panels to the American Society for Testing and Materials (ASTM) E84-04 “Standard Test Method for Surface Burning Characteristics of Building Materials” for smoke spread and flame spread. The panels have a Class 1 foam core. The foam components are formulated to have a flame spread of less than 25 units and smoke spread of less than 400 units.
Are ants and termites a problem in panels?
No more than in conventional construction. In climates where either termites or ants can cause problems, panel manufacturers recommend that all homeowners use the same preventive treatments (topical sprays around foundations, termite shields, etc.) that they would use in a stick-framed home. Note, however, that the foam within the panels does not provide food value for insects.
Is an ICS Eco-SIP a green building product?
Yes. SIP homes require considerably less framing lumber than a conventionally framed home. This saves trees. OSB is made from the 37% of a tree that is normally waste from making solid lumber. Solid lumber, as used in typical wood-frame homes, requires 63% of the wood from harvested trees. SIP homes, pre-cut in the factory, result in far less “job-site waste.” The small amount of wood scraps resulting from the SIP manufacturing process at the ICS plant is used for other products or recycled, rather than going into landfills.
Is it environmentally safe to make and use?
ICS uses a low-pressure foaming system designed to maximize the advantages of the foam properties. The cured foam is inert and non-hazardous. The foam process used by ICS uses no “ozone depleting substances”, such as chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs), hydrobromofluorocarbons (HBFCs), halon, methyl bromide, carbon tetrachloride, or methyl chloroform. Only EPA-approved materials are used by ICS. ICS polyurethane foam contains no formaldehyde. The foam contains agricultural-based oils derived from corn, sugar beets, and/or sugar cane. The foaming equipment is cleaned with hot water and a detergent, and the small amount of residue is safely disposable. ICS uses soy oil as a solvent in the factory to clean tools and parts.
How much are they? Do SIP walls cost more than frame walls?
When evaluating the cost of building with a SIP you need to look at the overall construction costs and long-term operating costs, not just the cost of the material. SIPs result in less waste, less field labor requirements (along with the associated field labor overhead costs, such as transportation, lodging, meals, benefits, etc.), much faster construction time (and fewer weather delays), lower HVAC equipment costs, and greater comfort. Long-term operating costs for utilities are greatly reduced. SIPs are even more competitive when the design is optimized to incorporate them. Consequently, architects design dimensions at two-foot and four-foot increments, engineer roof pitches at steeper angles to increase loft square footage, and make other similar adjustments to take full advantage of SIP capabilities. SIPs, therefore, usually result in lower overall building costs and better value.
Bottom line, are SIP buildings better?
Assuming the SIPS are properly designed, manufactured, and installed, a SIP-designed and built building will be stronger, will be built faster, will be more energy-efficient, will be a better value, and will be more comfortable.
