Continuous insulation: Construction’s new frontier

by arslan_ahmed | February 15, 2024 8:00 pm

[1]By Joseph Goley

The increased use of continuous insulation (c.i.) represents a fundamental shift in the way building insulation and energy efficiency efforts are approached in construction. As conversations around sustainability and energy conservation gain traction, c.i. has received greater attention among both commercial and residential customers.

Traditionally, insulation was installed in buildings primarily between structural elements, such as studs, creating the potential for thermal gaps that could lead to substantial heat loss and a reduction in overall energy efficiency. The use of c.i. challenges this conventional approach by wrapping the entire building envelope with a continuous layer of insulation to effectively mitigate thermal bridging and heat loss.

Insulation is becoming increasingly complex, and the role of c.i. continues to evolve as knowledge of building science and the environmental impact of construction practices grow. Since its introduction, c.i.’s use has remained relatively limited to the commercial sector. It remains rare for most top insulation contractors to install c.i. on residential projects. However, the importance of c.i. can no longer be ignored, as it has become a significant part of stricter building codes, including the 2021 International Energy Conservation Code (IECC). The code sets minimum requirements for energy-efficient residential and commercial building design and construction. For many of the current U.S. climate zones, the IECC has mandated c.i. to be a construction component on the exterior of the assembly. Some zones, however, will see different requirements due to extreme weather conditions. Builders and contractors working in zones with c.i.-related mandates must now determine how to best adapt to a technology that has become part of the code.

This insulation can, of course, present challenges. Its use, especially across the commercial side, may require adjustments to conventional construction methods, as well as a greater investment in training new talent and upskilling current employees. In addition, c.i. materials and techniques must meet rigorous performance standards to ensure long-term effectiveness. However, for a growing contingent of customers on both the commercial and residential sides, the benefits—energy savings, improved comfort, and a reduced environmental footprint—far outweigh the challenges. Such insulation is now a vital component of sustainable, future-proof building design, and there are unique paths available for those willing to be innovative and explore them.

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Growing customer demand

Public interest in environmentally conscious business practices has been higher than ever. With the construction industry generating an estimated 39 percent of the world’s carbon emissions, customers are seeking solutions to address the challenges in building design, with a strong emphasis on enhancing energy efficiency. In a recent global survey across several sectors, executives in construction and engineering have shown the most progress in prioritizing sustainability in design, with 47 percent considering it a top priority.¹

Therefore, the surge in customer demand for sustainable practices such as c.i. may be rooted in a growing awareness of environmental concerns and energy efficiency in construction, and in effect, a heightened demand for sustainable construction practices. In response, the construction industry is witnessing a transformative shift, and c.i. practices—which involve the installation of insulation materials forming an uninterrupted barrier across the building envelope—provide a compelling solution. Adopting c.i. practices work on several levels:

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It prevents heat loss or gain through the structure, leading to improved thermal performance and reduced energy consumption.
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It aligns with the regulatory and certification requirements that are becoming more stringent.
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It ensures compliance with energy efficiency and environmental impact standards set by governments and industry organizations.

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Beyond its energy efficiency benefits, c.i. practices also offer:

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Versatility in building design, allowing for greater aesthetic flexibility while maintaining performance.
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Empowerment for architects and designers to meet customer expectations for comfort and sustainability.

The growing customer demand for c.i. practices is pushing builders and contractors to explore new construction frontiers. Just like how the 2×4 has been phased out of exterior wall assembly construction in many parts of the U.S., there will come a time when insulation will no longer be restricted to just the cavity. It is not a trend, but a structured shift toward more environmentally responsible building solutions.

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Meeting new code requirements

As customer demands change, building codes have also undergone a significant shift. The 2021 building codes place a greater focus on c.i. for many U.S. climate zones, setting higher standards for energy performance and thermal resistance. This makes c.i. an essential component of virtually all new construction projects within these climate regions.

In hot and arid climate conditions, c.i. can help keep buildings cool while reducing the energy needed for air conditioning. In colder regions, c.i. contributes to better temperature control and reduced heating costs. Builders must adapt to these climate variations to ensure their projects meet the location’s performance and compliance standards. This underscores the need to find experienced partners who understand the use and execution of c.i.-related projects. The more knowledge and expertise available, the easier it will be for projects to pass the necessary inspections and regulations, regardless of the climate zone.

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Depending on the zone, current codes may 
also explicitly require the reduction of thermal bridging, which leaves little room for compromise when it comes to c.i. Therefore, it is essential for builders and contractors to be aware of the specific code requirements applicable to their specific geographic location.

While these building codes promote energy efficiency, they also pose challenges for builders. Finding alternative solutions that meet the stringent new code requirements will become more difficult. The 2021 building codes increasingly limit the types of alternative methods and materials available to contractors, pushing the industry toward the standardized use of c.i.

The 2021 codes represent a change in the construction industry, where reliance on c.i. will challenge builders to meet higher standards and explore new, innovative solutions. These codes are only now beginning to see full enforcement, so many builders and contractors can still elevate their knowledge and locate the right partners to avoid any complications that could arise from projects not meeting the updated codes.

Prescriptive versus performance

Builders face a critical choice between two paths to meet building code requirements for c.i.: the prescriptive path and the performance path. The prescriptive path offers a straightforward approach, in which builders must adhere to predefined guidelines, such as insulation R-values, window U-factors, and HVAC system efficiency ratings, with less room for customization.

This path offers the following advantages:

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Simplicity–It does not require the same level of modeling expertise as the performance path. Builders are able to follow predetermined guidelines and requirements.
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Compliance assurance–Compliance with building codes and standards is easier to demonstrate, as the requirements are clearly defined.

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This path also offers the following challenges:

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Limited flexibility–It may not be the most efficient choice for all projects, as it can limit the ability to customize solutions. This can be a significant challenge when aiming to optimize energy efficiency through advanced strategies like c.i.
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Limited savings–Builders may also miss out on cost and energy savings opportunities that could be realized with a more customized strategy.

The performance path is based on flexibility and customization, allowing builders to use innovative and tailored approaches to meet energy goals. This path considers various factors such as climate, occupancy, and equipment, to determine the building’s actual energy consumption and its compliance with prescribed standards. This path offers the following advantages:

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  Customization–It enables builders to create unique solutions tailored to a specific project. It allows for the use of various materials and strategies to achieve the best energy performance, which is especially helpful for c.i. projects where design and site conditions can vary significantly.

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Cost savings–By optimizing energy efficiency through performance modeling, builders can often reduce energy consumption and operational costs, resulting in long-term savings. This can be especially relevant in large commercial projects, where energy expenses constitute a significant portion of operational budgets.
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Environmental responsibility–This path emphasizes environmental responsibility tailored to the specific region and climate, aligning with the increasing global recognition of sustainable and eco-friendly construction practices.

The performance path also offers several challenges:

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Specialized expertise–It requires specialized modeling expertise, which not all contractors possess. This expertise involves understanding complex energy modeling software and interpreting results to make informed design and construction decisions.
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Additional time–The path may demand more time to account for the necessary modeling, data collection, and analysis, which can be a hurdle in projects with tight timelines or overlap with other on-site construction.

As builders continue to recognize the importance of energy efficiency and sustainability, the performance path is gaining traction, but this path requires locating partners who have the expertise to help builders make informed choices. In doing so, the construction industry can embrace c.i. as a valuable tool for enhancing energy efficiency and creating more sustainable buildings.

The role of c.i. in vapor control

Insulation that is continuous is not only advantageous in thermal performance, but depending on the material used, it can also play a role as a vapor retarder. A common factor in moisture-related problems within the building envelope, impacting structural integrity and indoor air quality (IAQ), some c.i. options—such as spray polyurethane foam (SPF)—aid in vapor control and can be a useful solution to moisture management issues common across many climate zones. This innovation allows for control over the dew point in the assembly, reducing the risk of condensation and other potential moisture issues.

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The climate factor

Effective moisture management through c.i.-specific vapor retarders requires a thorough understanding of the local climate. The climate influences factors such as temperature, humidity, and the direction of vapor drive, which can vary from one climate zone to another. Builders and designers must carefully assess these factors to make informed decisions regarding the selection and placement of materials and the overall strategy for controlling moisture.

By understanding how different types of c.i. can improve moisture management, increase longevity, and enhance structural performance, builders and contractors can gain a stronger competitive advantage in the industry.

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Upskilling the workforce

As the demand for energy-efficient and sustainable construction practices continues to grow, the need to hire and train the workforce is also urgent. When it comes to c.i., the workforce must not only understand the increasingly technical aspects of installation, but also the broader context of energy efficiency and sustainability. This understanding is vital to ensure the insulation is correctly applied to maximize its benefits and achieve increased energy performance.

Skilled insulation installers understand both the physical application of insulation materials and more elevated factors such as thermal bridging, air sealing, and moisture management. They can recognize the importance of proper detailing and how it impacts a building’s overall energy performance. As c.i. becomes more common, both builders and insulation contractors must invest in the following training programs to equip their workforce with sophisticated knowledge in:

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Technical expertise–Continuous insulation requires a deep understanding of various insulation materials, their properties, and their interaction with other building components. For instance, there are sequencing considerations that must be carefully coordinated because the timing of the work must align with other concurrent activities in the same location.
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Building science–Training should encompass the principles of building science, focusing on how insulation impacts the entire building envelope, including factors such as thermal performance, air leakage, and moisture control.
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Regulatory compliance–Given the evolving building codes and standards related to energy efficiency and sustainability, workforce upskilling is essential to ensure compliance with these regulations and avoid costly setbacks or legal issues.
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Technology integration–Continuous insulation often involves the use of new, emerging technologies and techniques. Keeping the workforce informed about these innovations can enhance a business’s competitiveness within the industry.

Skilled workers can ensure c.i. is applied effectively, minimizing energy waste and reducing operational costs for building owners. Proper insulation installation can also extend the life of a structure, saving money on maintenance and repairs over time—all added benefits to the customer. Further, it enhances the overall reputation of the construction industry, demonstrating its commitment to sustainable building practices. Finally, for the installers themselves, participation in comprehensive training programs gives them the opportunity for career growth and greater specialization.

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Beyond energy efficiency

Innovations and advancements in c.i. continue to deliver substantial improvements in both residential and commercial projects. However, these innovations do not just enhance the energy efficiency of buildings, they also provide solutions that prioritize aesthetics, ease of installation, and overall effectiveness. The result is c.i. technology that is more accessible and practical.

Aesthetics

Traditionally, insulation materials have been concealed beneath interior finishes. However, new materials are designed to be exposed as part of the building’s aesthetic, leading to their development with appearance in mind. Innovations such as textured and visually appealing insulated panels or insulated brick facades can offer architects and designers greater flexibility in creating attractive and energy-efficient exteriors. This aligns with the growing trend of energy-efficient buildings that also prioritize curb appeal.

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Ease of installation

One of the historical challenges to c.i. projects has been the complexity of installation. Recently, leading builders have looked for user-friendly products that are quicker to install. For instance, some c.i. systems now come with pre- or pre-shaped components, reducing the need for on-site modifications. This simplifies the installation process and saves both time and labor costs, making c.i. a more accessible design option.

Enhanced effectiveness

New insulation materials and systems can deliver higher R-values, reducing the overall thickness of the insulation layer while maintaining or even improving thermal efficiency. These advancements often incorporate features such as moisture management and reduced thermal bridging. Some materials to consider include:

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Sprayfoam insulation–Closed-cell sprayfoam insulation offers excellent R-values and can help eliminate thermal bridging.
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Mineral wool–Mineral wool insulation, such as rock wool or slag wool, is fire-resistant and provides good thermal performance.
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Extruded polystyrene (XPS)–XPS insulation boards are known for their high R-values, cost effectiveness, and ease of procurement.
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Polyisocyanurate (Polyiso)–Polyiso insulation boards are also sought after for their high R-values, moisture management, and low thermal conductivity.

These materials will shape the future of c.i. by making it more practical and appealing for builders, architects, and homeowners. As more energy codes and regulations prioritize energy efficiency, these advancements ensure c.i. will contribute to reducing operational costs and environmental impact, while enhancing overall quality and building aesthetics.

Conclusion

Since 2012, and much more so since 2021, adherence to this style of construction has become stricter. In the not-too-distant future, there may be fewer workarounds and less flexibility on projects. Builders will have to understand how to incorporate this into projects and who they can rely on to do it.

As c.i. becomes more ingrained in current and future building codes, businesses must evolve and develop operational strategies to thrive in an increasingly c.i.-prevalent world. Everyone—homeowners, commercial property owners, and tenants—wants properties built in a way that aligns with their values. Continuous insulation not only helps reduce a building’s carbon footprint, but also enhances indoor comfort and air quality. This makes it a compelling choice for consumers who prioritize sustainable living.

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As building codes increasingly emphasize the importance of enhancing thermal efficiency, insulation contractors have a unique opportunity to lead the charge. While the challenges can be daunting, from material selection and installation techniques, to the cost of training new and existing talent, the industry is already adapting and producing solutions that can make c.i. more accessible and efficient.

Builders who aspire to be industry leaders in the evolving construction landscape should strategically engage with reputable suppliers, cultivate diverse supply chains, and monitor market dynamics for potential disruptions and changes in trends. Given the established presence of c.i. in the commercial sector, locating experienced partners will be pivotal. Seasoned professionals well-versed in c.i. applications can help mitigate typical disruptions encountered in residential areas, fostering a strategic and competitive advantage.

Business owners can also invest in training and development beyond on-site talent and begin to equip sales and marketing teams with the tools necessary to effectively communicate the benefits of c.i. to current and prospective clients. This includes promoting a better understanding of how designs are changing and how this can lead to more efficient and sustainable buildings and homes.

The construction landscape has changed drastically over the past 50 years, and yet, the same businesses always win out. They are the ones who offer building performance solutions, invest in proper training, are at the forefront of innovation, and are not afraid to go where their customers demand they go. In this spirit of progress, it has become increasingly clear: the future of building insulation innovation includes c.i.

Notes

¹ Refer to the article by Forbes at www.forbes.com/sites/sap/2021/08/25/the-construction-industry-is-getting-greener-why-how-and-whats-changing/?sh=6a98f03052bc.

Author

As the manager and a third-generation leader for Goley Insulation, Joseph Goley has worked for the Dupo, Ill.-based insulation contractor since February 2019. Goley is a member of the Owens Corning CEE Customer Advisory Council, the Knauf Insulation Customer Advisory Board, Home Builders & Remodelers Metro East Association Board, and Southern Illinois University Edwardsville’s (SIUE’s) Construction Management Industry Advisory Board.

Source URL: https://www.constructionspecifier.com/continuous-insulation-constructions-new-frontier/

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