hot dry / mixed dry prototypes, wathen – castanos hybrid ... · –dmaic (define, measure,...
TRANSCRIPT
![Page 1: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/1.jpg)
Hot Dry / Mixed Dry Prototypes
Wathen –Castanos Hybrid Homes, Inc.
Duncan Prahl, RA
Sr. Research Associate, IBACOS Inc.
DOE Quarterly Meeting, Denver, CO
July 21, 2010
![Page 2: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/2.jpg)
Building America Team Meeting
Wathen Castanos Hybrid Homes, Inc.
• Company Profile:
• ~180 Homes per year in Clovis / Fresno CA
• First-time, Move-up and Empty-nester buyers
• House sizes from 1100 to 2700 square feet
• Started high performance homes in 2006
• Current standard practice ~ 48% WRT BA Benchmark
• Currently 36 employees
![Page 3: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/3.jpg)
Building America Team Meeting
Initial Evaluation - Mapping and Gap Analysis
2 days- mapped operational activities in 5 areas:
– Planning and Development, Product Design and Purchasing,
Home Sales and Marketing, Construction, and Customer
Care
– Identified key strengths and gaps as a builder of high
performance homes
– Strong corporate culture, trade relationships, brand
awareness, and reputation
– Integrated Design Process
From this activity 6 work improvement
groups were identified
![Page 4: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/4.jpg)
Building America Team Meeting
Work Improvement Groups (WIG’s)
• Company had to invent a new operational
model
– Company reduced staff by 2/3 from 2007 - 2009
• Developed cross functional teams to
address highest value gaps
• Training was provided to company and
trades on Building Science, Quality
Management, and Quality Tools
– DMAIC (Define, Measure, Analyze, Improve,
Control) process for WIG’s
• Applied for National Housing Quality Award
in 2010, received site visit by judging panel.
![Page 5: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/5.jpg)
Building America Team Meeting
Initial Evaluation - Technical
IBACOS Quality Assessment Results
• Two days of site evaluations.
• Overall score 3.2 (scale of 0 to 4)
– “Low Risk” Category
![Page 6: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/6.jpg)
Building America Team Meeting
Initial Evaluation - Technical
Best Practices Observed:
– Excellent HVAC duct installation.
– High efficiency equipment
– 92 AFUE furnace
– 14 SEER air conditioner
– Zoned distribution
– Rinnai tankless, gas fired water
heaters
![Page 7: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/7.jpg)
Building America Team Meeting
Initial Evaluation - Technical
Best Practices Observed:
– Grade I fiberglass batt installations.
– R-13 cavity + R-4 continuous exterior
insulating sheathing.
– Good air sealing of the enclosure.
![Page 8: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/8.jpg)
Building America Team Meeting
Initial Evaluation - Technical
Energy Performance of Existing Practices (Jan 2010):
– 48% above Building America Benchmark.
– Participating in Builder’s Challenge, California Build it Green,
& ENERGY STAR.
– 30% beyond 2008 CA Title.
– Average duct leakage <5%.
– Average building tightness < 3.5 ACH50.
– Taking advantage of every tax incentive and energy rebate
available to offset all energy upgrades.
– Homes marketed competitively at $/sq. ft. for region.
![Page 9: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/9.jpg)
Building America Team Meeting
Prototype – Design Strategies
Wathen Castanos Hybrid Homes Inc. wanted to roll out a
fresh product offering for a community development,
“Loma Vista”.
• Plan #200 is a 2000 square foot, 3 bedroom ranch
style home.
– IBACOS encourage the builder to consider moving the HVAC
system and ducts to inside conditioned space.
– The cost to do a conditioned attic proved too high for the
builder’s price point.
– Very concerned about marketability of 8’ ceilings in areas of
the house.
![Page 10: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/10.jpg)
Building America Team Meeting
Plan 200
![Page 11: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/11.jpg)
Building America Team Meeting
Prototype – Specification Package
The point deficiency to get
from 48% to 50% beyond
BAB would have to be made
up in system efficiency and
an enhanced building
enclosure.
Net positive cash flow to the
consumer of ~$935 / year
Rating for this design
package:
RESNET HERS Index - 53
CA HERS I – 46
CA HERS II – 68
(see barriers…)
Component 2010 Base Package Prototype
Concrete Slab Uninsulated Uninsulated
Exterior Walls
2x4 16" o.c. R-13 + R-4 cont. sheathing (R19 knee walls)
2x4 16" o.c. R-15+ R-4 cont. sheathing (R19 knee walls)
Roof
Attic floor - R-38 + Radiant Barrier
Attic floor - R-49 + Radiant Barrier
Exterior Doors R-4 R-4
Windows U-.34, SHGC-.25 U-.32, SHGC-.25
Building Air Tightness 3.5 ACH50 2.7 ACH50
Mechanical Ventilation Exhaust with pressure relief Exhaust with pressure relief
Heating 92 AFUE 94.7 AFUE
Cooling 16 SEER 18 SEER
Ductwork R-8 in unconditioned R-8 in unconditioned
Water Heater Tankless, gas .82 EF Tankless, gas .98 EF
Appliances All Energy Star All Energy Star
Fluorescent Lighting 100% 100%
Photovoltaic System variable 3.7 kW
% Better than Building
America Benchmark48.4% 52.6% & 70% w/PV
![Page 12: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/12.jpg)
Building America Team Meeting
Prototype – Design Strategies
• This demonstrates their
commitment to taking
this specification
package to community
scale production
• Wathen Castanos Hybrid Homes has been adamant
that the resulting prototype product would still fit into a
price point that would be competitive in their market.
![Page 13: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/13.jpg)
Building America Team Meeting
Prototype – Design Strategies
• Strategies to achieve a tighter building envelope (to get
from 3.5 to below 3.0)
– Addition of seal sill that layer up under stucco weep screed.
– Glued drywall to top and bottom plates & around openings.
![Page 14: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/14.jpg)
Building America Team Meeting
Prototype – Design Strategies
• Builder was already:– Sealing all penetrations through plates and enclosure.
– Sealing all window and doors between R.O.s and frames.
– Sealing all penetrations through the drywall.
• Actual blower door test results indicate a total leakage rate of 2.7 ACH50. Not amazing, but not bad for California, open frame construction.
![Page 15: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/15.jpg)
Building America Team Meeting
Prototype – Design Strategies
• Additional wall R value was achieved by using Johns
Manville Spider® blown in fiberglass.
![Page 16: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/16.jpg)
Building America Team Meeting
Prototype – Design Strategies
• Though attic insulation was increased to R-49 (from R-38) raised heel trusses were priced but not included.
• Some designs require raised heels for aesthetics
![Page 17: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/17.jpg)
Building America Team Meeting
Design Challenges & Barriers
System Sizing
• Initial modeling indicated that a 2 ton AC was sufficient.
– Total cooling load was 20,888 Btuh
• The builder wanted to use the Bryant Evolution system.
• The 2 ton was discontinued and a 2 ½ ton wasn’t
available.
• Therefore a 3 ton system was installed.
• Again, the industry is faced with manufacturing split AC
systems that are high efficiency and small enough for
low load, high performance homes.
![Page 18: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/18.jpg)
Building America Team Meeting
Challenges and Barriers
• Bringing Ducts inside conditioned space– Aesthetic concerns
– Footprint of the HVAC unit
– Noise concerns
• How much is enough?– 50% package is possible, but incremental step above 48%
builder standard practice is marginal.
– Even if we “threw everything at it” we’d only be getting in the mid 50% savings
• CA HERS I, II & RESNET Ratings– T-24 vs. 2006 IECC reference homes
– States rights vs. national uniformity
![Page 19: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/19.jpg)
Building America Team Meeting
Buyer response
• Since the opening of this home, WCHH has offered a PV package as an included upgrade. Buyers can opt for any other options instead. The majority are taking the other options.
• “The home is efficient enough, I’ll take the granite countertops.” is the common response to this offering.
• The 3.7 kW photovoltaic system cost $13,940 with a
rebate of $7709 for a final cost to the builder of $6231
to the builder.
![Page 20: Hot Dry / Mixed Dry Prototypes, Wathen – Castanos Hybrid ... · –DMAIC (Define, Measure, Analyze, Improve, Control) process for WIG’s ... BAB would have to be made up in system](https://reader031.vdocument.in/reader031/viewer/2022020416/5cd8072888c993262f8d3bf4/html5/thumbnails/20.jpg)
Building America Team Meeting
Next Steps
• Implement a model Quality Management System
within the organization
– Way to document and standardize procedures for HP
homebuilding
– Identify operational best practices for translation to other
building companies
– Track operational metrics to demonstrate benefits of making
HP a basic operational strategy
• Evaluate Prototype
– Are incremental strategies enough to maintain market
leadership?
– Re-evaluate systems strategies