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Transcript of Conventional Roofing - Impacts of Insulation Strategy and Membrane Color
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Conventional Roofing Assemblies: Measured Benefits of Light to Dark Roofing Membranes & Alternate Insulation Strategies PHILADELPHIA BEC – SEPTEMBER 16 2014
GRAHAM FINCH, MASc., P.ENG – PRINCIPAL, BUILDING SCIENCE RESEARCH SPECIALIST
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“RDH Building Sciences” is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s) earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of Completion for both AIA members and non-AIA members are available upon request.
This program is registered with 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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Copyright Materials
This presentation is protected by US and International Copyright laws. Reproduction,
distribution, display and use of the presentation without written permission of
the speaker is prohibited.
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Learning Objectives
At the end of this program, participants will be able to:
1. Understand how to evaluate and select an appropriate conventional
roof membrane type and color for various climate zones
2. Understand how to evaluate and design the most appropriate
insulation strategy for a conventional roof. Learn how different
insulation materials and hybrid insulation combinations will behave
differently in-service and have a varying effective R-value depending
on temperature.
3. Understand how different insulation strategies and roofing
membranes affect heating and cooling energy consumption in
different building types.
4. Observe case studies where recommended roofing membrane and
insulation designs have been implemented.
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Presentation Outline Conventional Roofing Designs and Current Issues Conventional Roofing Field Monitoring and
Research Program Field Results – Membrane & Insulation Strategies Selecting Optimum Roofing Color and Insulation
Strategy for Energy Efficiency Case Studies
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Conventional Roofing Designs & Current Issues
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Recap: Conventional Insulated Roofs
Most common low-slope roof application in North
America
Insulation installed above structure, protected by
roofing membrane - Insulation is typically foam plastic
(polyiso, EPS), though mineral fiber also used
Roofing membrane is exposed to temperature, UV,
traffic – needs to be durable
Roof slope typically achieved by tapered insulation
unless the structure is sloped
Attachment of membrane/insulation can be: adhered,
mechanically attached, loose laid ballasted, or
combination to resist wind uplift
Wood, concrete, or steel structure substrate
Air barrier and vapour control layer below insulation on
top of structure (depending on climate/design)
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Current Issues With Conventional Roofs
Roofing membrane issues Insulation movement – Thermally induced
Causes membrane ridging and stresses
More movement with thicker amounts of insulation (becoming more
common) and certain insulation types
More movement in roofs with darker colored membranes
Insulation movement - Long term shrinkage, expansion, contraction Gaps between insulation boards, induced membrane stresses
Cover board /protection board failure – delamination, softening, organic
growth, fastener corrosion
Moisture trapped in insulation and roof assembly from wetting
during construction or from small leaks in-service Becoming more common to install leak detection monitoring within
conventional roofs and find this out – what to do about it? How to adjust
monitoring?
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Membrane Ridging & Insulation Movement
TPO over gypsum board and polyiso
SBS over wood fiberboard and XPS
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Membrane Ridging & Insulation Movement
2 ply SBS over Fiberboard & XPS
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Insulation Movement & Membrane Failure
2 ply SBS over EPS
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Insulation Movement & Membrane Failure
2 ply SBS over Polyiso over EPS taper package
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Wood Fiberboard Coverboard Issues
Wood fiberboard cover-board wetting and delamination
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Cover Board Failures & Membrane Delamination
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Gypsum Cover Board Issues
Wetting, Softening & Facer delamination
Wetting & Fungal growth Wetting & accelerated fastener corrosion
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Insulation Shrinkage & Heat Loss
2 ply SBS over single layer of mechanically attached Polyiso
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Insulation Shrinkage Study
Polyiso has had a reported history of board shrinkage – both initial and long-term Related to manufacturer, mix, temperature, moisture, and age Results in gaps between the insulation boards and induces
stresses introduced into roof membranes Past monitoring shows varying amounts of ongoing
shrinkage – primarily influenced by age of product when installed
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Polyiso Shrinkage Monitoring Study
Year 1 – 0.2% (2 mm in 1200 mm)
Shri
nkag
e -
mm
20102009
0
2
1
3 1/8”
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Polyiso Shrinkage Monitoring Study
Year 4 – 0.2% to 0.7% (2-8 mm in 1200 mm)
Shri
nkag
e -
mm
8
0
2
4
6
2009 2013
Year 1
1/4”
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Roof Membrane Color Considerations
Roof membrane or ballast color (solar absorptivity)
influences surface temperature Darker colors (more absorptive, less reflective)
results in higher temperatures, more assembly
movement and membrane stress, higher cooling
loads, lower heating loads Lighter colors (less absorptive, more reflective)
results in lower temperatures, less assembly
movement and membrane stress, lower cooling
loads, higher heating loads
Balance needed between membrane durability,
assembly movement, heating and cooling loads
Programs such as LEED have points for use of highly
reflective roofs regardless of energy implication and
local climate.
Long term impacts and soiling of light colored roofs
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Membrane Soiling – 5 years, Poor Slope TPO
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Conventional Roofing Field Monitoring Study
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Guiding Purpose of the Study – Why?
Quantify performance of different colors of exposed roof membrane
(white, grey, black)
What impact does LEED have on roof energy performance
Quantify performance differences of different insulation types:
stone wool, polyiso and hybrid insulation combinations
Quantify combined impact of membrane color and insulation strategy
Observe impact of the long-term soiling of white SBS cap sheets
Monitor long-term shrinkage/movement of insulation and relative
humidity/moisture levels within insulation
Laboratory testing of material properties we didn’t know
While Certain materials used for Phase 1 of study – key findings are
applicable to all membrane & insulation types
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Roof Membrane Colors
3 different 2-ply SBS roof membrane cap sheet colors (white reflective, grey, black)
White Reflective Cap Sheet:
SRI 70, Reflectance 0.58, Emittance 0.91
Grey Cap Sheet:
SRI 9, Reflectance 0.14, Emittance 0.85
Black Cap Sheet:
SRI -4, Reflectance 0.04, Emittance 0.85
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3 Different Insulation Strategies
Stone wool - R-21.4(2.5” + 3.25”, adhered)
Polyiso - R-21.5(2.0” + 1.5”, adhered)
Hybrid - R-21.3(2.5” Stone wool + 2.0” Polyiso, adhered)
Design target: Each Assembly the same ~R-21.5 nominal
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Insulation and Cap Sheet Layout
9 unique roof test areas, each 40’ x 40’ and each behaving
independently Similar indoor conditions (room temperature) and building use
(warehouse storage) Climate Zone 4
Figure 1 Study Building and Layout of Roof Membrane Cap Sheet Color and Insulation Strategy
Polyiso
Hybrid
Stone wool
120’ 120’
Grey
White
Black
PolyisoHybrid
Stonewool
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Sensor Selection and Installation
Temperature
Heat Flux
Relative Humidity
Moisture Detection
Displacement
Solar Radiation
Heat Flux Relative Humidity & Moisture Detection
Displacement
Temperature Solar Radiation
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Sensor Positioning
T - TemperatureRH - Relative HumidityHF - Heat FluxM - Displacement
M
M
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Roof and Sensor Installation
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Roof and Sensor Installation
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Roof and Sensor Installation
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Measured Insulation Performance
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My Most Common Designer Question Lately: What R-value is My Insulation?
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Laboratory Testing of Insulation R-values
3rd Party ASTM C518 thermal transmission
material testing performed as part of
monitoring study
Polyiso and stone wool insulation
removed from site + aged 4 year old
polyiso samples from prior research
study
Wanted to know actual R-value as
installed and temperature impacts to
calibrate sensors
Testing performed at mean insulation
temperatures from 25, 40, 75, and 110°F to
develop R-value vs temperature
relationships
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Laboratory Testing of Project Insulation
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
20 40 60 80 100 120
R-value per inch
-IP Units
Mean Temperature of Insulation - °F
Installed & Aged Insulation R-values per Inch - Based on Mean Temperature (°F)
Polyiso - Maximum Polyiso - Average Polyiso - Minimum
Polyiso - Aged (4 years) Stone Wool - Average
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Applying Laboratory Testing to the Field
Design R-values for each assembly ~R-21.5
Stone Wool -2.5” + 3.25”, Weight 26.7 kg/m2, Heat Capacity – 22.7 kJ/K/m2
Polyiso - 2.0” + 1.5”, Weight 4.6 kg/m2,
Heat Capacity – 6.8 kJ/K/m2
Hybrid – 2.5” Stone wool over 2.0” Polyiso, Weight 14.3 kg/m2, Heat Capacity – 13.7 kJ/K/m2
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Varying R-value of Field Roof Assemblies
14
15
16
17
18
19
20
21
22
23
24
10 20 30 40 50 60 70 80 90 100 110 120 130 140
Effective Assembly R-value
-IP Units
Outdoor Membrane Surface Temperature (Indoor, 72°F)
Effective Roof Insulation R-value - Based on Roof Membrane Temperature
Stone Wool (Initial or Aged)
Hybrid (Initial Average)
Hybrid (Aged)
Polyiso (Initial Average)
Polyiso (Aged)
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Field Monitoring Findings
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Field Monitoring Results
Monitoring from first 2
years shown today
Plan to monitor for 5
years for long-term
trends and aging effects
Data shown here to
demonstrate:
1. Impact of Membrane
Color
2. Impact of Insulation
Strategy
3. Combined Impacts
SENSOR CODING: W – whiteG – grey B – blackSW - stone wool ISO – polyiso ISO-SW – hybrid
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Study Findings: How Big of a Difference does Membrane Color Have?
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White Membrane Soiling & Reflectance
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
May Jun Jul Aug Sept Oct Nov Dec Jan Feb Mar Apr Annual Rated
Reflectance
Reflectance of Membranes
White (high) White (low) Grey
*
*Rated reflectance was measured using a different method than was used in the field study.
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32
50
68
86
104
122
140
158
176
194
0
10
20
30
40
50
60
70
80
90
May Jun Jul Aug Sept Oct Nov Dec Jan Feb Mar Apr
Temperature [°F]
Temperature [°C]
Monthly Average of Daily Maximum Membrane Temperatures and Maximum Membrane Temperature for Each Month by Membrane Colour
White Grey Black White - Maximum Grey - Maximum Black - Maximum
* *
*W-ISO-SW had significant data loss in August and September and is removed from the average for those months.
Color – Impact on Surface Temperatures
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Color - Differences in Net Heat Flow
-200
-150
-100
-50
0
50
100
May Jun Jul Aug Sept Oct Nov Dec Jan Feb Mar Apr Annual
Daily Energy Transfer [W·hr/m² per day]
Monthly Average Daily Energy Transfer by Membrane Colour
White Grey Black
OutwardHeat FlowInward
Heat Flow
Monthly Average Daily Energy Transfer by Membrane Color
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Color & Calculated Degradation
Relative degradation rate calculated from measured cap sheet
temperatures
Further study needed to quantify age and physical property
effects
Black roof with stone wool directly below the membrane doesn’t get as hot
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Study Findings: How Big of a Difference does the Insulation Strategy Have?
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Insulation Impact on Peak & Lagging Membrane & Metal Deck Temperatures
Ro
of
Mem
bra
ne
Meta
l D
eck
0
10
20
30
40
50
60
70
80
90
Jun 30 0:00 Jun 30 6:00 Jun 30 12:00 Jun 30 18:00 Jul 1 0:00
Temperature [°C]
Roof Membrane Cap Sheet Temperatures
W-ISO T-CAP
W-ISO-SW T-CAP
W-SW T-CAP
G-ISO T-CAP
G-ISO-SW T-CAP
G-SW T-CAP
B-ISO T-CAP
B-ISO-SW T-CAP
B-SW T-CAP
Outdoor-T
24
26
28
30
32
34
36
Jun 30 0:00 Jun 30 6:00 Jun 30 12:00 Jun 30 18:00 Jul 1 0:00
Temperature [°C]
Metal Deck Temperatures W-ISO TEMP-DECK
W-ISO-SW TEMP-DECK
W-SW TEMP-DECK
G-ISO TEMP-DECK
G-ISO-SW TEMP-DECK
G-SW TEMP-DECK
B-ISO TEMP-DECK
B-ISO-SW TEMP-DECK
B-SW TEMP-DECK
176°F
140°F
104°F
68°F
97°F
75°F
86°F
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Heat Flux Data – Heat Loss vs Gain
-30
-25
-20
-15
-10
-5
0
5
10
15
Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
Heat Flux [W/m²]
Heat Flux Sensors
W-ISO HF
W-ISO-SW HF
W-SW HF
G-ISO HF
G-ISO-SW HF
G-SW HF
B-ISO HF
B-ISO-SW HF
B-SW HF
SENSOR CODING: W – white, G – grey, B - blackSW - stone wool, ISO – polyiso, ISO-SW - hybrid
Heat Loss
Heat Gain
1 W/m2 = 0.32 Btu/hr/ft2
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Heat Flow – Heat Loss vs Heat Gain
Winter vs. Summer
-25
-20
-15
-10
-5
0
5
10
Feb 21 Feb 22 Feb 23
Heat Flux [W/m²]
Heat Flux Sensors
W-ISO HF
W-ISO-SW HF
W-SW HF
G-ISO HF
G-ISO-SW HF
G-SW HF
B-ISO HF
B-ISO-SW HF
B-SW HF-25
-20
-15
-10
-5
0
5
10
Jun 30 Jul 1 Jul 2
Heat Flux [W/m²]
Heat Flux Sensors
W-ISO HF
W-ISO-SW HF
W-SW HF
G-ISO HF
G-ISO-SW HF
G-SW HF
B-ISO HF
B-ISO-SW HF
B-SW HF-25
-20
-15
-10
-5
0
5
10
Jun 30 Jul 1 Jul 2
Heat Flux [W/m²]
Heat Flux Sensors
W-ISO HF
W-ISO-SW HF
W-SW HF
G-ISO HF
G-ISO-SW HF
G-SW HF
B-ISO HF
B-ISO-SW HF
B-SW HF
W- white, G-grey, B-black, SW-stone wool, ISO - polyiso
Heat Loss Heat Gain
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Heat Flow – Variation with Insulation Strategy
-25
-20
-15
-10
-5
0
5
10
Jun 30 0:00 Jun 30 6:00 Jun 30 12:00 Jun 30 18:00 Jul 1 0:00
Heat Flux [W/m²]
Heat Flux Sensors
W-ISO HF
W-ISO-SW HF
W-SW HF
B-ISO HF
B-ISO-SW HF
B-SW HF
Heat Loss
Heat Gain
SENSOR CODING: W – white, B - blackSW - stone wool, ISO – polyiso, ISO-SW - hybrid
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Heat Flow – Variation with Insulation Strategy
SENSOR CODING: SW - stone wool, ISO – polyiso, ISO-SW - hybrid
-25
-20
-15
-10
-5
0
5
10
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Heat Flux [W/m²]
Heat Flux Sensors
G-ISO HF
G-ISO-SW HF
G-SW HF
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Net Annual Impact of Insulation Strategy
0
100
200
300
400
500
600
-150
-100
-50
0
50
100
May Jun Jul Aug Sept Oct Nov Dec Jan Feb Mar Apr Annual
Degree Days [°C·days]
Daily Energy Transfer [W·hr/m² per day]
Monthly Average Daily Energy Transfer by Insulation Arrangement
ISO ISO-SW SW Heating Degree Days (18°C)
OutwardHeat Flow
InwardHeat Flow
1 W/m2 = 0.32 Btu/hr∙ft2
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Other Findings to Date
Insulation Movement monitoring ongoing
Observing daily insulation swings
Seeing some long-term movement of
insulation, but also movement of metal deck
structure interfering with long-term data
Relative Humidity and moisture movement
ongoing
Seeing harmless seasonal movement of built-
in water vapor through insulation
Water vapor also moves energy – latent heat
Cut-tests confirm roofs all dry and no issues
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Optimizing Membrane Color and Insulation Strategy for Energy Efficiency
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Energy Consumption and Membrane/Insulation Design
Calibrated energy modeling used to compare roof
membrane color/solar absorptivity & insulation strategy White, Grey or Black Roof Membrane Polyiso, Stone wool, or Hybrid insulation approach
• Stone wool has lower R-value/inch but higher heat
capacity and higher mass
• Polyiso has a higher R-value/inch (varies with temperature)
and has a lower heat capacity and lower mass
• Hybrid approach has stone wool over top of polyiso which
moderates temperature extremes of polyiso insulation –
makes polyiso perform better
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Energy Consumption and Membrane/Insulation Design
Energy modeling performed for a
commercial retail building
(ASHRAE building prototype
template)
Results calibrated with
temperature/heat-flux data from
monitoring study
Input temperature dependant &
aged R-values into energy model –
base R-20 roofs
Help to select the optimum
insulation and membrane color
combination for energy efficiency
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Energy Modeling of Temperature Dependant Insulation R-values
Input lab measured temperature dependant insulation R-value for polyiso and
stone wool into energy model
Heating energy for Climate Zone 4 (Vancouver) shown here, R-20 insulation
Impact is significant enough that should be accounted for
Results in different design rankings of lowest to highest energy consumption
36
37
38
39
40
41
42
43
44
Dark Roof Gray Roof White Roof
Annual Heating Energy Consumption, kWh/m
2
Model Default - Constant Conductivity
Polyiso
Stone wool
Hybrid
36
37
38
39
40
41
42
43
44
Dark Roof Gray Roof White Roof
Annual Heating Energy Consumption, kWh/m
2
Revised Model - Temperature Dependent Conductivity
Polyiso
Stone Wool
Hybrid
Total Energy Consumption includes walls, windows, air leakage, slab on grade, +roof
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0
10
20
30
40
Black Roof Gray Roof White Roof
Annual Heating Energy Consumption,
kWh/m2
Polyiso
Stone Wool
Hybrid
Aged Polyiso
Aged Hybrid
Most Energy Efficient Roofing Combination in Philadelphia Region – Climate Zone 4
0
10
20
30
40
Black Roof Gray Roof White Roof
Annual Cooling Energy Consumption,
kWh/m2
Polyiso
Stone Wool
Hybrid
Aged Polyiso
Aged Hybrid
0
10
20
30
40
Black Roof Gray Roof White Roof
Annual Space-Conditioning Consumption,
kWh/m2
Polyiso
Stone Wool
Hybrid
Aged Polyiso
Aged Hybrid
Lower is Better – Total Energy Includes Loss through Roofs + Walls, Floor, Windows, Air Leakage etc.
12 kBtu/ft2/yr
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Most Energy Efficient Roofing Combination?
0
20
40
60
80
100
120
1 - Miami 2 - Houston 3 - San Francisco 4 - Baltimore 5 - Vancouver 6 - Burlington VT 7 - Duluth 8 - Fairbanks
Annual Heating Energy, kWh/m2
Climate Zone
Black - Aged Polyiso
Black - Stonewool
Black - Aged Hybrid
White - Aged Polyiso
White - Stonewool
White - Aged Hybrid
0
20
40
60
80
100
120
1 - Miami 2 - Houston 3 - San Francisco 4 - Baltimore 5 - Vancouver 6 - Burlington VT 7 - Duluth 8 - Fairbanks
Annual Cooling Energy, kWh/m2
Climate Zone
Black - Aged Polyiso
Black - Stonewool
Black - Aged Hybrid
White - Aged Polyiso
White - Stonewool
White - Aged Hybrid
Commercial Retail Building Heating Energy – kWh/m2/yr
Commercial Retail Building Cooling Energy – kWh/m2/yr
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Most Energy Efficient Roofing Combination?
Lighter membrane, stone wool or hybrid is better for same design R-value
Darker membrane, stone wool or hybrid is better for same design R-value
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Summary – Key Points
Research and Field Monitoring Study Findings
Design R-value may change in service – all types of insulation are
affected to varying degrees – Is not Static
In addition to design R-value - heat capacity and latent moisture
transfer within insulation has an impact on temperatures and
energy transfer
Optimization of heating and cooling based on roof membrane
color and insulation strategy suggested
Careful selection of insulation strategy and membrane color will
have a positive impact on roof assembly performance
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Case Studies
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Stone Wool Insulation in Conventional Roofing
R-value of stone wool is R-3.7/inch
compared to a R-4 to R-6/inch for
polyiso and R-4/inch for EPS Need thicker stone wool to achieve same
R-value as polyiso in design
If polyiso kept closer to indoor
temperatures, then it has a higher
effective R/inch (closer to LTTR)
Insulate the Polyiso!
Hybrid insulation provides good blend
of material properties and economics Tapered insulation packages available:
EPS, Polyiso, or Stone wool
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Case Study 1 - High-rise Re-Roof
Assembly: 2-ply SBS torched to 2” asphalt impregnated stone wool over 2” polyiso (adhered)
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Case Study 2 – Residential Re-Roof
Assembly: 2-ply SBS torched to 2” asphalt impregnated stone wool, over 2” polyiso, over polyiso tapered package (mechanically attached)
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Case Study 3 – Heritage Re-Roof
Assembly: 2-ply SBS torched to 1” stone wool asphalt impregnated cover board adhered to 2” stone wool, mechanically fastened through EPS taper package
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Case Study 4 – New Roof over First Tallest Wood Structure in North America
Design & Architectural Renders: Michael Green Architecture (MGA)
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Case Study 4 – New Roof over First Tallest Wood Structure in North America
R-40+ Conventional Roof Assembly – 2 ply SBS, 4” Stonewool, 4” Polyiso, Protection board, Tapered EPS (0-8”), Torch applied Air/Vapor Barrier(Temporary Roof), ¾” Plywood, Ventilated Space (To Indoors), CLT Roof Panel Structure (Intermittent)
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Case Study 4 – New Roof over First Tallest Wood Structure in North America
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Case Study 5 – What Would RDH Do?
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Designer and Roofing Contractor Feedback
Stone wool insulation relatively easy and fast to install. Heavier than
EPS/polyiso boards, but doesn’t blow away Stone wool insulation lays flat and takes up uneven surfaces, tight
board installation, very few gaps compared to more rigid foam
boards Stone wool is softer than polyiso and potentially softens during
construction from foot traffic – not issue in open field areas, but
compression can occur in high traffic areas prior to covering Typically address with extra asphalt protection board overlay.
Thicker insulation build-up for stone wool compared to polyiso due to
R-value differences, may be an issue where thickness is at a premium
or could be issue during re-roof around existing doors and curbs etc. Watch mechanical fasteners without a protection board. Adhesive with stone wool must be applied and set-in quickly before
foam expands. Slightly different process than with EPS/polyiso.
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Recommended Conventional Roofing Strategies for Energy & Durability
Design to provide good balance of cost, thickness, & performance (energy, durability, membrane life)
Roof Membrane – grey or other neutral color for northern climates, light in south
Adhered system with stone wool insulation as top layer / cover board (30-50% of total insulation R-value)
Layer of polyiso (below staggered) joints with taper package
Self adhered/torched sheet air/vapour barrier membrane (temporary roof) over substrate
Adhered layers preferred instead of mechanically attached, where possible to balance cost
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This concludes The American Institute of Architects Continuing Education Systems Course
Graham Finch Dipl.T, MASc, P.EngRDH Building Sciences [email protected]