Building Envelope
Consultants, Ltd.
Architects · Engineers · Roof Consultants Insured: World Class Manufacturing Group, Inc. Claim #: 2386301 I hereby certify that this plan, specification, or report was prepared by me or under my direct supervision and that I am a duly Licensed Professional Engineer under the laws of the State of Wisconsin.
3/25/2015 Digitally Signed Date Donald P. Lomax WI Professional Engineer License No: E-37215
Aerial Image of subject building with front elevation facing South (Bingmaps.com) North at top of page
Waukesha, WI Chesterfield, MO Edina, MN Chicago, IL
www.building-envelope.net
888-549-1930
March 25, 2015 Joe Jacques Cincinnati Insurance PO Box 343 Suamico, WI RE: Insured: World Class Manufacturing Group, Inc. Loss: 36600 County Rd J North Bayfield, WI Claim #: 2386301 Mr. Jacques: On February 11, 2015, Cincinnati Insurance retained Building Envelope Consultants, Ltd. to perform a site inspection. The inspection was performed over two dates; March 11-12, 2015. The weather was cool, dry and partly sunny on both dates. The following were present at one or both of the inspections:
a. Melissa Gwidt, World Class Manufacturing Group, Inc (WCM) b. Jeremy Maiwald, WCM c. Krista Paulus, Impact Seven d. John Czarnecki, Summit Adjusting Service e. David Balistreri, Building Envelope Consultants, Ltd f. Kyle Stair, Building Envelope Consultants, Ltd
The purpose of the inspection was to:
a. Determine if recently reported interior leaking is associated with damage to the roof from a previous ice/snow damage claim.
b. Provide opinion as to the source of the interior water leak(s) if no such link to the previous event is determined.
c. If associated with previous ice/snow damage claim, provide opinion as to repair scope.
This report is based upon a collection and analysis of data acquired from primary and secondary sources. Primary sources include:
a. Visual inspection of the accessible interior and exterior areas of the subject building necessary to complete the assignment.
b. Infra-red imaging of interior areas using a FLIR brand, model EX-320 c. Digital measurements of interior/exterior temperature and relative humidity using an
EXTECH brand digital sling psychrometer model RH401.
BEC, Ltd. Cincinnati / World Class Manufacturing Group, Inc.
Page 2 www.building-envelope.net
888-549-1930
Secondary sources include historical and other information provided by others including:
a. Joe Jacques, Cincinnati Insurance i. Acord Property Loss Notice (4/12/2014)
ii. Schedule of Locations iii. Moe and Nevin Letters 4-23-2014, 5-15-2014, 6-17-2014, 6-24-2014 iv. Moe and Nevin Photos 4-18-2014 v. Moe and Nevin Estimate 6-17-2014
vi. Paul Davis Report 4-21-2014 vii. Dahl Construction Estimate 6-11-2014
viii. Dahl Construction Invoice 1315 ix. Blakeman Plumbing & Heating Proposal 20140113 w/supporting metal roof docs. x. Blakeman Plumbing & Heating Invoices; 23836, 23837
xi. Handwritten Financial Notes by Unknown Author xii. Loss photos by unknown photographer of damaged items at time of initial loss;
1. Four B&W images 2. Eighteen color images
b. Melissa Gwidt, WCM i. WCM Building Plans – JNMIII Architects
1. Preliminary Bid – 7-19-2006 (seven sheets) 2. Final Review – 10/25/2006 (five sheets) 3. Site Plan – 12/11/2006 (one sheet)
ii. Email Correspondence with Hans Dahl 5-20-2014 1. Thermal Design Technical Bulletin 18: Mold & Performance of Wet Insulation
c. Jeremy Maiwald, WCM i. Diagram of locations of historic and current leaking in manufacturing area.
d. Hans Dahl – Dahl Construction e. David Johnson, Guardian Insulation (mbi) f. J.P. Korpi, Paul Davis Emergency Services g. Terry Bollett, Moe & Nevin Insurance Adjusters h. John Czarnecki, Summit Adjusting Services i. Thermal Design, inc – Super Saver Insulation Guide (Attached)
Building Envelope Consultants Ltd. personnel involved in the field inspection or compilation of this report:
a. David Balistreri, RRC, CDT, Level I Thermographer b. Donald Lomax, PE c. Kyle Stair, Field Technician d. Lindsey Fredricksen, Administrative Assistant
For the purpose of this report the front elevation of the subject building is considered facing South.
BEC, Ltd. Cincinnati / World Class Manufacturing Group, Inc.
Page 3 www.building-envelope.net
888-549-1930
Background: The subject building was constructed about 2007 on behalf of WCM by Impact Seven and other municipal agencies (Town of Bayfield, WI). WCM (INSURED) has occupied the building as a triple net lease tenant since the buildings’ construction. The building was reportedly designed by James Nelson McKellin III, AIA (Stillwater, MN). Construction documents (plans) provided by the INSURED do not reflect the as-built condition of the facility and cannot be considered fully reliable. According to the INSURED, the building was reportedly constructed by a general contractor who is no longer in business. The building is heated with liquid propane heat in both the offices and manufacturing areas. Heat is also generated by the machinery utilized within the building. The facility is used as a CNC produced parts manufacturing facility. According to the INSURED;
· The manufacturing area houses approximately 20 single operator machines that use water based open flowing coolant.
· The facility was running two work shifts per day · The average employee count per shift was ten. · Each shift typically runs approximately 5-7 machines.
According to the INSURED, sometime in early April, 2014 a significant quantity of accumulated snow and ice slid from the roof surface, causing some vent pipes to be sheared or otherwise damaged at roof and side wall locations. This allowed a significant amount of melt and rain water to enter the building envelope and leak into office and manufacturing areas of the building. The damaged vents were repaired by Blakeman Plumbing & Heating (Ashland, WI) and other damage, including but not limited to, replacing exterior wall panels/gutters and other interior refurbishing was completed by Dahl Construction Co. (Bayfield, WI). The insulation manufacturer (Guardian mbi) was contacted to address concern regarding the long term performance of wet insulation. The insured was instructed by the Guardian Insulation to consider opening sections of the facer where wet insulation was located, allow any trapped water to drain and the insulation to dry during the summer season. They were then to tape closed any openings made, and the insulation would likely perform as intended. This procedure was performed by Dahl Construction Co. (Dahl) as well as the INSURED’s maintenance personnel. However, not all openings made in the insulation facer were closed by the end of the 2014 summer. During the 2014-2015 winter season, water has intermittently dripped from the ceiling within the manufacturing area. The locations are sometimes the same as they had been in 2014 but other locations had also developed (see attached diagram at end of report). The insured is concerned the conditions are related to the earlier roof damage.
BEC, Ltd. Cincinnati / World Class Manufacturing Group, Inc.
Page 4 www.building-envelope.net
888-549-1930
Observations: The subject was a single story, pre-engineered metal building manufactured by Foremost Buildings Inc. (Jefferson, WI). It had a simple gable, 1”:12” slope roof covered with galvanized steel, structural, trapezoidal rib roof panels. Wall panels were pre-finished steel, “R-panel” style. The building was rectangular with an approximate foot print of 150’ x 150’. The manufacturing area also contained shipping and receiving work areas. The east elevation contained the primary dock doors for shipping and receiving though one overhead door was also located on each of the north and south elevations for vehicle access at grade. According to the plans provided by the INSURED;
· The building sits over poured-in-place concrete footings and stem walls with an interior reinforced slab on grade.
· The steel structure has six steel frames supported at mid span with a single steel column. The secondary framing members (purlins and girts), were inset.
· The walls and ceiling of the building envelope were insulated using a “super saver” insulation system (see attached brochure for such system).
Offices were located at the central portion of the south elevation within the main building line. The offices were primarily framed using light gauge steel and other conventional light industrial materials such as drywall, fiberglass batt insulation, acoustical suspended ceiling trays and carpeted floors. The insulation within the manufacturing area had a white “pvc” facer that covered the space between the frames. The frames and insulation straps remained exposed. Overall the facer appeared intact except at isolated areas where holes had been created to allow for water drainage and where retroactively installed mechanical equipment was located. Where retro-installed equipment was located, the facer was opened at purlins to accommodate threaded support rods. Those openings had not been sealed and were located primarily along the western side of the building. Isolated areas of patch tape were evident on the face of the insulation. Ripples, sags and pillowed areas of the insulation were present, though overall, the insulation facer appeared tight and in good visual condition. The offices were heated with a single conventional forced air furnace while the manufacturing space used radiant heaters. Lighting throughout the facility was composed primarily of natural daylighting through windows and fluorescent tube fixtures.
BEC, Ltd. Cincinnati / World Class Manufacturing Group, Inc.
Page 5 www.building-envelope.net
888-549-1930
The manufacturing area thermostats were set at an average of 73 degrees Fahrenheit. The temperature, relative humidity and dew points were checked within the interior of the manufacturing area and outside the building using an Extech brand digital sling psychrometer and infrared thermometer (model RH401). The following data was obtained; Interior/MFG:BEC Day 1 ~2:45 PM 65F Day 2 ~9:20 AM 63F 26% RH 54% RH 29F DP 46F DP Exterior: BEC Day 1 ~2:45 PM 48F Day 2 ~ 9:20 AM 42F 20% RH 44% RH 9F DP 21F DP The interior of the building was scanned using a FLIR brand Infra-red camera (Model EX320). Areas on the wall and roof surfaces showed evidence of heat loss. Thermal variation between adjacent materials (such as purlin and insulation face) varied between 0 and 15 degrees Fahrenheit. In the manufacturing area it was apparent the insulation was holding moisture in some locations due to the sagging of the insulation and thermal patterns encountered. No active water drips were occurring anywhere within the building regardless of area when BEC was present in the afternoon on the first site visit day (However, active drips were reported to have occurred that morning). Active drips were discovered on the morning of the second site visit day. Readily visible condensation was also apparent on the facer of the insulation in the manufacturing area. Thermal patterns encountered also suggested condensation was occurring throughout the interior of the insulation system at nearly every purlin location under the west slope. Some purlins locations had greater thermal differential than others. East slope purlin locations and insulation showed fewer similar conditions. One sagging location of insulation was identified from the ground on the second inspection day and an aerial platform provided by the INSURED was used to gain access to it. Without opening the insulation it was apparent the insulation held substantial liquid water by lifting the insulation face. Adjacent to this location, liquid water dripped from the face of the insulation to the manufacturing floor. Also in close proximity to the trapped water was an insulation opening at a purlin where a threaded rod was located. Without cutting the insulation, BEC was able to fit and extend a hand to underside of the roof deck. What appeared to be an insulation condensation blanket with another facer was encountered (This could not be confirmed without destructive testing which was beyond the scope of this assignment). A tape measure was sent into the void and the cavity measured approximately eleven inches from base of purlin to underside of roof deck.
BEC, Ltd. Cincinnati / World Class Manufacturing Group, Inc.
Page 6 www.building-envelope.net
888-549-1930
Conclusions: Based on our training and experience, and to a reasonable degree of engineering certainty, BEC forms the following conclusions; There was no evidence of any latent damage to the roof, as a result of the previous roof damage claim. Furthermore there was no evidence the conditions that existed at the time of the early 2014 claim were contributing to the current interior moisture problem. Important supporting evidence for this opinion includes (but is not limited to);
1. Dripping water from the ceiling of the manufacturing space discovered at a time when no precipitation or snow/ice was present on the roof surface.
2. No evidence of storm/ice related openings in the roof covering or associated penetrations. 3. Moisture encountered predominantly away from penetrations associated with the
previous claim. These findings indicate the moisture that was dripping from above was not sourced by active melting snow or precipitation entering through openings in the roof. Furthermore it is our opinion the primary source for the moisture collected within and on the surface of the ceiling insulation in the manufacturing space is directly related to ambient water vapor condensing (and collecting) on and within the insulation system (there was no evidence of any significant moisture accumulation over the office space area, though a condensation drip was evident at a heating duct). Important supporting evidence collected during our investigation supporting this opinion includes (but is not limited to);
1. Variability between interior/exterior and morning/afternoon temperature and humidity levels.
2. Thermal variability among intersecting building components identified by Infra-red imaging of the interior of the facility.
3. Openings in the insulation vapor retarder. 4. Reports by the insured, the dripping occurred only in the AM hours, were evident only
during the winter season and were primarily located under the west roof slope when not associated with a roof penetration.
These reports correspond with times of the lowest temperature and highest relative humidity, and locations where the highest concentration of openings in the vapor retarder of the insulation system was located. Though some residual water content may remain within the insulation bed where roof penetrations were damaged in early 2014, any moisture not in the immediate vicinity of those penetrations would not have any link to that event. Of those penetrations that could successfully be imaged at the time of our inspection, none showed evidence to support a claim the insulation was damaged and required replacement as a direct result of the damaged vents of 2014.
BEC, Ltd. Cincinnati / World Class Manufacturing Group, Inc.
Page 7 www.building-envelope.net
888-549-1930
Without destructive testing, it is not possible to ascertain the full degree the insulation may be damaged and therefore BEC cannot recommend any full scope to repair. BEC does believe, however, any insulation mandated for replacement can be completed from within the facility with little to no disruption of production, and on a targeted approach. BEC also recommends the HVAC systems be checked by a qualified HVAC systems engineer to determine the proper air changes the manufacturing facility requires to balance the interior ambient air in order to diminish the propensity for condensation to occur. Other more practical considerations are to allow the insulation to drain, and seal all openings in the vapor retarder to restrict air flow through the system.
BEC, Ltd. Cincinnati / World Class Manufacturing Group, Inc.
Page 8 www.building-envelope.net
888-549-1930
Closing & Certification:
We, David Balistreri, President of Building Envelope Consultants, Ltd and Donald P. Lomax, professional engineer of the State of Wisconsin, certify that to the best of our knowledge and belief;
i. The statements of fact contained in this report are true and correct.
ii. We have no present or prospective interest in the property that is the subject of this report and no personal interest or bias with respect to the parties involved.
iii. Our engagement in this assignment was not contingent upon developing or reporting pre-
determined results.
iv. Our compensation for completing this assignment is not contingent upon the development or reporting of a pre-determined outcome that favors the cause of our client.
v. This report is not a construction document and is not meant to be used for the purpose of
acquiring building permits.
vi. We reserve the right to provide additional or amended opinions should further information become available regarding this matter.
Following is an accompanying photographic record highlighting the issues and concerns discussed in this report as well as other pertinent supporting data. If you have any questions please do not hesitate to call our office. Sincerely,
David Balistreri, RRC, CDT Level I Thermographer President
Donald P. Lomax, PE Vice-President
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 1: Site identification. Front (South) elevation.
Photo 2: Facing north in Laboratory where it had reportedly sustained significant water damage during previous winter claim.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 3: Water had pooled across the floor from within lab room into adjacent office space to east of lab. Lab entrance door to office area in background.
Photo 4: Southwest corner of manufacturing space where much of the worst leaking had occurred previous and where it was reported to be leaking once more.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 5: Facing the west wall of manufacturing area where drips of water were active during morning hours.
Photo 6: Looking up at ceiling along west elevation. Note insulation surface shiny due to moisture on surface. Note: holes poked in insulation facer to allow for water to drain.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 7: Manufacturing area includes heat from liquid propane (LP) fueled heaters.
Photo 8: East roof slope overview facing north. Note snow guards in place along eave and upslope of vent stacks.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 9: Typical roof panel lap condition.
Photo 10: Roof overview facing north along ridge.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 11: West roof slope facing north.
Photo 12: Snow guards installed upslope of roof vents.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 13: Roof vent flashing without readily apparent opening.
Photo 14: Soil vent with inverted boot.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 15: Soil vent boot with weathered fissure.
Photo 16: Group of roof penetrations on west slope.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 17: Roof vent flashings without readily apparent opening.
Photo 18: Roof vent flashing without readily apparent opening.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 19: Roof vent flashing without readily apparent opening.
Photo 20: Roof vent flashing without readily apparent opening.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 21: Plastic snow guard installed in surface mount fashion.
Photo 22: Metal snow guard installed in surface mount fashion.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 23: Gutter installed along east eave.
Photo 24: Gutter along west eave had been removed.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 25: Interior ambient temperature and humidity at floor level.
Photo 26: Interior dew point temperature and humidity at floor level
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 27: Lower thermostat reading.
Photo 28: Upper thermostat reading.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 29: One heating unit thermometer in off position.
Photo 30: Exterior ambient temperature and humidity at grade.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 31: Exterior dew point temperature and humidity at grade.
Photo 32: Space over offices viewed from floor of mop closet. Note dark drip stains on wall insulation
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 33: Discolored insulation over office area.
Photo 34: Active drip under HVAC duct. No rain or snow melt outdoors while drip occurs.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 35: View up toward ceiling over drip location.
Photo 36: Water stain at pressure tank location.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 37: View across space over offices facing west.
Photo 38: View across space over offices facing east.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 39: Area under west roof slope at south end of manufacturing area. Note vapor retarder is open where threaded rod is installed (highlighted).
Photo 40: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 41: Area under west roof slope at south end of manufacturing area.
Photo 42: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 43: Area under west roof slope at west eave of manufacturing area. Note red laser spot corresponds to approximate location of central spot in following IR image.
Photo 44: Infrared image of previous photo. Note bright spots correspond to punctures in insulation facer.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 45: Ceiling over office spaces. Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 46: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 47: Ceiling over office spaces. Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 48: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 49: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 50: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 51: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 52: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 53: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 54: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 55: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 56: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 57: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 58: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 59: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 60: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 61: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image. Note open vapor retarder where threaded rod is located.
Photo 62: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 63: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 64: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 65: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 66: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 67: Exterior dew point temperature and humidity at grade level (day 2).
Photo 68: Exterior ambient temperature and humidity at grade (day 2).
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 69: Interior ambient temperature and humidity at floor level (day 2).
Photo 70: Interior dew point temperature and humidity at floor level (day 2).
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 71: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 72: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 73: insulation blanket holding pool of water. Note water dripping from vapor retarder face (highlighted).
Photo 74: Depth of insulation follows depth of purlin.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 75: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image. Note open vapor retarder where threaded rod is located.
Photo 76: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 77: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 78: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 79: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 80: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 81: Ceiling over manufacturing space Note red laser spot corresponds to approximate location of center point on following IR image.
Photo 82: Infrared image of previous photo.
36600 County Road J North Bayfield, WI
Claim #: 2386301
Photo 83: Infrared image of area under west slope.
Attachments
1. Building Plan with Leak Location Marked by Insured
2. Super Saver Insulation Brochure
Thermal Design's liner systems reduce these costs:
HVAC
Lighting
Electrical
Finishes
Utilities
Erection
Table of contents:
Featuring superiorJM Formaldehyde-free™ fiber glass insulation
2 Simple Saver System
3 Johns Manville Insulation
4 New Roof Construction
6 New Wall Construction
8 Common Uses
10 Retrofit Roof & Walls
12 Safety & Fall Protection
13 Performance
14 Simple Saver Synergy DesignSM
16 Performance Guarantee
Over 40,000 installations since 1983
JM Formaldehyde-free™ fiber glass insulation | Third-Party Hot Box Tested | Ten-Year Limited Material Warranty | Free Synergy Design Consultation
US Patent #5901518
Simple Saver System®
The #1 specified high R-value insulation system for metal buildings
Buildings cost less with the
2 | www.thermaldesign.com Copyright © 2012 Thermal Design, Inc. All Rights Reserved. SSS_Brochure_JM_PM 042511v2.indd | Printed in U.S.A.
Superior Insulation SystemThe Simple Saver System is designed to create the average depth space needed for the full specified insulation thickness plus deflection and deliver the maximum possible insulation performance. Conductive structural members penetrating through the insulation require thermal breaks and may reduce overall performance. Properly sealed ceiling and wall systems prevent air infiltration and isolate the conductive steel structure from the conditioned space air. The Simple Saver System provides both low U-values and low emissivity values, stopping over 90% of all three types of heat transfer.
Engineered Strength for Safety – FREEThe Simple Saver roof liner system is engineered to be strong and durable for job site safety, is OSHA Compliant and a patented fall arrest system. The super strong liner system withstands the rigors of installation and provides workers beneath with protection from falling objects. The liner system then permanently supports the insulation. This limits the liability of owners, designers and contractors (Standard 29 CFR Definitions–1926.751 "Controlling Contractor"). The fall protection benefits are free, but only with the legitimate, patented Simple Saver System (Patent # 5901518).
Class A Fire Safety Rating – FREEThe vapor retarder fabric liner of the standard Simple Saver System is self-extinguishing as it complies with: ASTM 1136, Types I through VI; NFPA 701 Large Scale; flame spread of 25 or less per ASTM E-84 (equivalent to NFPA 255, ANSI 2.5 or UL/ULC 723). Special order or modified products may be tested upon order by the purchaser for the costs of the tests.
Absorbs Sound – FREEProvides excellent yet inexpensive acoustic finishes where conventional suspended ceilings are not appropriate or not in the budget. Standard system has 75% sound absorption (NRC 0.75). This superb by-product of the Simple Saver System comes free with the system. Excellent for gymnasiums, arenas, houses of worship, manufacturing, entertainment spaces and multipurpose rooms.
Some minor wrinkles may be visible due to the large pieces of support fabric used.
Finishes and Decorates – FREEThe Simple Saver System's free, bright white appearance is often used as an exposed interior finish in buildings. Purlins and girts are hidden, eliminating the cost to paint them. Various colors and strap patterns may be specified to obtain unique aesthetic appearances. The ceiling and wall surfaces are washable and easy to maintain.
Brightens Interiors – FREEThe bright white, light reflective surface enhances efficiency of the lighting system, eliminating about 30% of the number of light fixtures. Light reflectance tests of up to 85% are achieved. Savings of lighting equipment, wiring and electricity result in substantial dollar savings for the building owner. Low ultraviolet producing light
sources or UV filtered lenses are necessary to prevent UV degradation and obtain optimum service life.
Helps Prevent Condensation – FREEThe high strength Simple Saver fabric liner isolates the cold conductive purlin and girt surfaces from the inside conditioned air, reducing the exposed conductive purlin and girt surface areas from about 50% of the roof and wall areas to a fraction of 1%. Water vapor transmission rate
is ≤ 0.02 grains per hour/sq. ft. for the standard fabric liner. Factory-made, triple extrusion welded
seams are for safety and uniquely pressure resistant to assure the very low vapor permeance and vapor retarder
integrity as opposed to thousands of staple holes or hidden, unsealed lap joints typical with laminated insulation.
*Other cut sizes available.
BYTHERMAL DESIGN
Second layer of JM Formaldehyde-free™ fiber glass insulation, alternative thermal break or both.
First layer of JM Formaldehyde-free™ fiber glass insulation
Custom fabric liner system made to fit each bay
Gridwork of steel retainer straps*
*A grid pattern is standard with topside installations in new buildings. Retrofit standard strap pattern is single direction. System components are sold as a designed package and not sold separately.
Simple Saver System®
JM Formaldehyde-free™ fiber glass insulation
Thickness Pre-Installed R-Value Width* (in) Length
9" R-30 48 • 60 35'
8" R-25 48 • 60 40'
6" R-19 36 • 48 • 60 • 72 50'
4" R-13 36 • 48 • 60 • 72 75'
3 1/2" R-11 48 • 60 • 72 75'
3" R-10 36 • 48 • 60 • 72 100'
Copyright © 2012 Thermal Design, Inc. All Rights Reserved. SSS_Brochure_JM_PM 042511v2.indd | Printed in U.S.A. www.thermaldesign.com | 3
Fabric Liner The UVMAX® coated fabric is a proprietary woven, high density polyethylene fabric which provides a Class A fire retardant rating. Our UVMAX® white maximizes total light reflectivity. The fabric liner can also be perforated for unique building conditions. The durable Simple Saver fabric liner is over 300% stronger than typical metal building insulation facings. Request a free sample!
Specific fabric color may not be an exact match of the examples show above.
Superior Recovery with Less Itch and Less DustFiber glass insulation is made of two things: glass and a binder. The binder glues the thin glass threads together. This is “bonded” fiber glass insulation, found in batts and rolls. Other manufacturers use formaldehyde in their binder. JM Formaldehyde-free™ fiber glass insulation utilizes an innovative acrylic binder that eliminates binder-related formaldehyde emissions.
The U.S. Environmental Protection Agency recommends limiting exposure to formaldehyde as much as possible. Source: Environmental Protection Agency
When installers open the packaged insulation rolls, they quickly notice two things; superior recovery and the fiber glass is virtually odorless. JM Formaldehyde-free™ fiber glass insulation uses high quality glass in their manufacturing process which benefits installers with less dust and less itch during and after installation.
Once installed, it will not "off-gas" formaldehyde in the indoor environment. That means formaldehyde won't leak from the insulation in your walls and ceilings. Formaldehyde is added to many other building products, it makes sense to use products without it whenever possible.
Strapping – Simple Saver System uses corrosion resistant, 1” wide x .020 UVMAX® strapping that is twice as strong with a dependable 100,000 lbs /square inch tensile strength. Strapping is color matched to the fabric and ships in 1,500 ft. oscillated wound coils. Each installed strap is continuous, no field splicing is needed.
Fasteners – Simple Saver fasteners have sealing washers and are color matched to the fabric liner system. Available in multiple types and sizes depending upon the substrate type.
Syseal® Tapes & Sealants – Thermal Design has formulated special products for fast application and the optimal seal strength of the Simple Saver fabric liners.
Product Description PEBS Blanket™ and Microlite® "L" are general purpose fiber glass insulation blankets made without formaldehyde for use in both roofs and walls of pre-engineered metal buildings, post frame buildings, joist buildings and other structure types.
Specification Compliance ASTM C 991, Type I / ASTM E 136 / ASTM E 84 Flame Spread Classification of 25/50 or less flame spread/smoke developed rating.
Fresh Insulation JM Formaldehyde-free™ fiber glass insulation is shipped from the manufacturer directly to the job site. Insulation rolls are carefully packaged for savings in freight, ease of handling, protection of quality and have excellent recovery once opened on site.
Upper layer of insulation
Purlin
Simple Saver fabric liner system
Lower layer of insulation
Metal deck
Steel strap
JM Formaldehyde-free™ Fiber Glass Insulation
BlackWhite or
Super White Silver Aspen Toni Taupe™Other Colors
Available
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Single Layer SystemsThermal breaks are recommended between roof decking and the structure to reduce thermal conduction.
Double Layer Systems The upper layer of fiber glass is installed between roof decking and the structure to reduce thermal conduction.
Blown-in Systems Blown-in systems fill nearly every crack and crevice for maximum thermal performance.
Multiple layers and appropriate space is required for any of these systems.
Thermal spacer blocks may be added to increase insulation space and further reduce conduction.
New Roof Construction
The Simple Saver System® is a patented fabric liner system that minimizes insulation compression and isolates the conductive purlins from the inside conditioned air.
Production RatesThe Simple Saver System is designed for rapid topside installation and optimum insulation performance with 80% fewer field seams. The production rates below are conservative ranges for installation of a single or double-layer system in typical purlin roofs under average conditions with an experienced crew.
Roof: 150-200 sq. ft./man-hour
Walls: 120-170 sq. ft./man-hour
In the summer of 2008, Thermal Design commissioned a third party time study which concluded production rates of over 235 sq. ft./man-hour. This equates to less than 25 cents per sq. ft. installation labor costs based on a $50 per hour labor rate. Contact Thermal Design for time study details.
Common Roof Structures In Which The System May Be Used
Z-Purlin Bar Joist
C-Purlin Wood Precast/Poured Steel Beam ConcreteTee
The Simple Saver fabric liner system is custom made for each order and the Syseal® fabric liner typically spans the entire bay’s width and length in one piece. It is supported by a grid pattern of tensioned steel straps installed below the purlins or joists. This creates the required space for full insulation thickness between the structural members. In multi-layer systems the upper layer of unfaced insulation may be installed over the structural members with minimal compression.
Install the longitudinal and traverse steel strapping to create the strap platform.
Large custom-sized fabric liner installs quickly on the steel strap platform.
View of fabric liner positioned on strap platform and fastened to the structure.
Simple Saver® Roof Systems
Pre-installedR-value
LowerLayer(s)
UpperLayer(s)
R-19 6" -
R-25 8" -
R-29 6" 3"
R-30 9" -
R-30 6" 3 1/2"
R-32 6" 4"
R-35 8" 3"
R-38 8" 4"
R-43 9" 4"
R-49 9" 6"
R-49 12" 3 1/2"
R-52 12" 4"
R-57 12" 6"
R-60 9" 9"
R-68 12" 9"
R-76 12" 12"
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Electric Box
SimpleFastener
HoleStrap
ChannelStrut
AngleHanger
ThreadedPlate
Hanger
ThreadedHanger
Bar JoistHanger
SammyX-Press™
beforeFastening
purlin bracing purlin bracing
New Roof Construction
Items to consider when ordering buildings.
Standardized Purlin SpacingsCustom made insulation widths are available however, by simply specifying or requesting standardized purlin spaces from the building manufacturer, you will increase your installa-tion productivity, reduce waste and shorten lead times for delivery. Specify 3', 4' and 5' purlin spacings from the building manufac-turer that match standard insulation widths. There is no reason why there should be more than one non-standard width spacing on each side of the ridge of any building.
Rafter Brace Clips The design of the rafter brace attachment to the bottom plane of the purlin speeds installation of the liner system and provides superior vapor seal. Specify one of these common details when ordering your building.
Performance Comparisons of R-30 SystemsValues are based on insulation assemblies in a 5' purlin space with a standing seam roof and thermal block. The hot box tested assemblies were tested in the horizontal position with vertical upward heat flow. Performance will vary with structural spacing and assembly orientation. Visit www.thermaldesign.com for more information.
A. ASTM-C 1363 hot box tests, Oak Ridge National Laboratory
B. Finite Element Modeling, NAIMA MB304 (8/06), System 3
Pre-Installed R-value:
U-value:
Installed R-value:
Simple Saver "Liner System"
4.7% lossR-30 (R19+R11)
U-0.035 A
R-28.6
Long Tab System"Filled Cavity"
39.7% lossR-29 (R19+R10)
U-0.057 B
R-17.5
Sag & Bag"Double Layer"
47.0% lossR-30 (R19+R11)
U-0.063 A
R-15.9
Fabric liner trimmed and sealed to the rafter.
Install JM Formaldehyde-free™ fiber glass insulation between and over purlins.
Finished ceiling and wall system in school gymnasium.
Clips now available in white or black!
Hanging Methods These are some of the many common hangers that can be used with the Simple Saver System without the need to cut the fabric liner. Compression seals or caulk type sealants may be used with any hanger type. Contact Thermal Design at 800-255-0776 for additional hanger details or sourcing.
1 2 3
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New Wall Construction
Fast-R™ Wall Insulation Hanger
Preformed and punched Fast-R hangers attach to the girts or wall surfaces.
These save time and hold the insulation in permanent position.
Packed 80 hangers/ box, 32” long x 1” wide, 20 Gauge
One box covers approximately 1,000 sq. ft.
Metal Building Wall SystemThe Simple Saver wall insulation system is installed completely from the inside, out of the wind and weather. Unfaced insulation lengths are simply cut to fit the girt spacings and then impaled onto Fast-R® insulation hangers. This prevents the fiber glass from sagging. The fabric liner is then installed on the inside plane of the wall to isolate the insulation and conductive girts from the conditioned air. This also provides a clean, bright, finished appearance.
Filling The Full Girt Depth Is RequiredSingle layer systems help speed the wall sheeting process and a thick single layer of unfaced insulation is preferred to two layers of compressed laminated insulation in walls. The Simple Saver single layer liner systems prevent bulging and dimpling of the metal wall panels which is common with laminated insulation compressed between the panels and through-fastened to the sub-structure.
The full depth should be filled to minimize loss of thermal performance caused by convection currents. Wall panel laps, trim and flashing should be sealed per codes to prevent air infiltration into the insulation. Syseal Building Wrap™ is also available for the ultimate in air leakage resistance.
The Simple Saver insulation system installs in virtually any wall structure type to make any building envelope energy efficient.
Simple Saver roofliner system
Fast-R™ insulation hanger
Simple Saverwall liner system
Third-partybase angle or 'C' channel
Wall girt
Quik-Stop™ or Snap-R™
thermal break
JM Formaldehyde-free™ fiber glass insulation
(unfaced & full designed thickness)
Quik-Stop™ thermal break tape applied to outside of girts.
Secure the Fast-R™ insulation hangers to the wall structure with the punched arrows bent 90 degrees from the vertical.
Insulation is cut to fit the full space and impaled on the Fast-R™ hangers.
Metal Building Wall Detail
Quik-Stop™ Thermal Break
Insulative foam thermal break with adhesive back. Recommended between metal wall panels and metal sub-structure with single layer insulation systems.
Minimizes thermal conduction between metal wall panels or decking and the metal sub-structure.
108' long x 3 " width x 3/16" thick
Snap-R® Thermal Block
Individual “snap-on” EPS thermal blocks save installation time and will not blow away with the wind.
24" long x 4" wide x designed thickness.
Standard above flange thicknesses are 3/8" and 1" thick which accommodates a 3" purlin flange. Other thicknesses are available to create the required space for any desired insulation thickness to fully expand!
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New Wall Construction
**Two insulation layers and stand-off brackets may be required to provide necessary insulation depth.
Other combinations are available upon request.
Installed performance is currently under study and indicate up to a 50% reduction of installed performance in vertical orientation using typical low density fiber glass metal building insulation.
Call Thermal Design at800-255-0776 for analysis of your specific application.
Stand-off Bracket shown with optional steel or wood girt attached.Girts are required for the attachment of optional protective liner panels.
Stand-off Bracket System for Hard Walls (conditions may vary).
Simple Saver roofliner system
Fast-R™ insulation hanger
JM Formaldehyde-free™ fiber glass insulation (unfaced & full design thickness)
The Stand-off Bracket™ used to create the required space for the insulation on hard wall systems
Simple Saverwall liner system
Masonry, precastor stud wall
Third-party base angle or 'C' channel
Third-party perimeter foundation insulation
Liner Panel Optional steel or plywood wall liner panels protect the bottom of the wall fabric liner system.
Stand-off 'Z' Brackets™Brackets are purchased separately and include fasteners. Other sizes available.
The Simple Saver System® may be installed in a variety of common wall structures.
JM Formaldehyde-free™ fiber glass is full thickness and fills the girt depth.
Fabric liner with steel straps installedto create clean, finished look.
Finished wall and ceiling in manufacturing facility.
*Masonry *Precast concrete
*Flat surfaces require stand-off brackets
Wood or steel stud
Metal building or post frame wall
Hard Wall Detail
3”4”6”8”
Simple Saver® Wall Systems
Preinstalled R-Value Thickness
R-10 3"
R-11 3 1/2"
R-13 4"
R-19 6"
R-25 8"
R-30 9"
R-38** 12"
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Common Uses
Gymnasiums & Arenas
Tennis Facilities
Indoor Ice Rinks
Equestrian Centers
Manufacturing Facilities
Warehouses
Transportation Centers
Distribution Facilities
Fire & Emergency
Schools & Universities
Worship Facilities
Community Centers
Aviation Hangars
Agricultural Buildings
Wineries
Detention Centers
Put our experience to work for you.
Over 40,000 installations since 1983.
The Simple Saver System® is ideal for finishing and insulating buildings of all applications.
Call 800-255-0776 for free design and specification assistance.
Many Buildings and Uses
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Common Uses
Aviation Hangars
Agricultural Buildings
Wineries
Detention Centers
Retail Stores
Offices
Big Box Stores
Vehicle Showrooms
Convention Centers
Casinos
Entertainment Venues
Theaters
Municipal Buildings
Federal & State Facilities
Military Facilities
Public Works & Recycling
One Insulation System
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Retrofit Roof & Walls
Install steel strap platform and the fabric liner across the bay.
Pull or blow-in JM Formaldehyde-free™ fiber glass insulation between the purlins.
Fasten and seal the fabric liner edge to the rafter.
Before After
Durability & Maintenance
Stapled facing seams have opened up and the vapor retarder facing has cracked and ripped, allowing moisture to reach the conductive metal deck panels.
The one piece, triple extrusion welded seam vapor retarder fabric is a high strength, durable fabric liner that holds up to the abuse inside the building and is washable.
The Choice Is Simple
The building has an unfinished appearance, compressed insulation and conductive structure is exposed to the conditioned air.
Retrofitting with the Simple Saver System will provide a clean, bright finished appearance, maximize insulation performance and isolate conductive structure from the conditioned air.
Thermal & Acoustical
Performance
Compressed insulation results in poor thermal and acoustical performance.
Added insulation greatly increases thermal performance and acoustic absorption.
Vapor Retarder
Placement
The vapor retarder faced insulation is compressed over the tops of the purlins which typically are seasonally below the dew point temperature resulting in condensation, corrosion and shortened roof life.
The vapor retarder is properly placed below the purlins to help prevent condensation and corrosion which extends the life of the roof.
Heat Transfer
Purlins and girts act like fins on a radiator. In the winter heat escapes the building and in the summer, heat radiates into the building.
Purlins and girts are completely covered by the Simple Saver fabric liner system which also encapsulates the insulation space.
The exposed structure absorbs light and casts shadows requiring unnecessary lighting.
The fabric liner system is designed to have excellent light reflectivity and diffusion with the purlins and girts fully covered.
Light Reflectivity
A 50% savings of conditioning costs is common by retrofitting with the Simple Saver System®.
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• Lowers Energy Costs to 50% or More • Improves Interior Appearance• Increases Light Levels with White Liner System• Helps Prevent Condensation • Increases Thermal Efficiency• Creates Quiet Interiors with Acoustic Absorption• Prevents Corrosion and Extends Roof Life• Seals Off Dust-Collecting Structure • Lowers Maintenance Costs
Install Today, Save TonightMost existing commercial and industrial buildings have obsolete energy systems for today's higher energy costs. Pre-engineered metal buildings are particularity obsolete because of the poor insulation methods which compress the insulation and leave the conductive steel purlins and girts exposed. Retrofitting with the Simple Saver System and JM Formaldehyde-free™ fiber glass insulation will start saving immediately and dramatically enhance the interior appearance. Tax deductions may apply.
Advanced InstallationSignificantly higher production rates are achieved if the Simple Saver System is installed before other trades (plumbing, electric, heating). The system can also be installed after those trades have completed however the installation is more time consuming and will be more expensive.
The Retrofit Simple Saver System® can be installed in virtually any roof or wall structure.
Simple Saver retrofit roof system
Existing compressed insulation
JM Formaldehyde-free™ fiber glass insulation
Fast-R™ insulation hanger
Simple Saver retrofit wall system
(see wall study reference on page 7)
*Standard retrofit strap pattern is one direction, 30-inches on-center. Retrofit grid pattern system also available for small additional cost.
Joists or Trusses
Existing insulation
Simple Saver fabric liner system
Added unfaced or blown-in JM
Formaldehyde-free™ fiber glass insulation
Steel straps* Bar joist or truss
Metal deck or built-up roofMetal Buildings
Existing compressed
insulation
Simple Saver fabric liner system
Added unfaced or blown-in JM
Formaldehyde-free™ fiber glass insulation
Steel straps* PurlinOptional Snap-R™ or Quik-Stop™
Optional Snap-R™ or Quik-Stop™
Metal deck
Retrofit Roof & Walls
The values shown above are the values of the added Simple Saver System insulation thickness. For a total insulation value, add the R-value of the retrofit insulation system to the existing installed performance. The performance of retrofit systems varies and minor performance adjustments will be required for conductive structures estimated to be about 10%.
Based upon purlin spacing 60" on-center with faced insulation compressed between the structure and the through-fastened steel panels. Based on pro-posed ASHRAE 90.1-2007 Addendum bb.
Retrofit Roof SystemsR-Value of added insulation subject to space available. Higher values are available
upon request.
Insulation Thickness
Added Pre-Installed
R-Value
3" R-10
3 1/2" R-11
4" R-13
6" R-19
8" R-25
9" R-30R-Value of Existing Compressed
Metal Building Insulation
Pre- InstalledR-Value
U-ValueInsulation
+ Structure R-value
R-10 (3") U-0.184 R-5.4
R-13 (4") U-0.174 R-5.8
R-19 (6") U-0.151 R-6.6
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Safety & Fall Protection
Patented Fall ProtectionThe Simple Saver Liner System quickly installs from lifts and the workers are then safe to work from above without the need to be restrained by cumbersome lanyards or restricted to controlled decking zones. Effective January 1st of 2001, Thermal Design added the patented fall protection as a free standard feature of the Simple Saver System at no additional cost. The Simple Saver System requires two critical strap end fasteners to safely pass the test and achieve safe fall protection.
Custom Project Drawings and Instructions Detailed, custom project drawings are standard for each building. Specific strap and fastener locations, bay spacings, fabric sizes and exact insulation sizes and placements are all provided for the Simple Saver System to achieve a safe effective installation.
Training & Technical Support Reduce your liability, keep installers safe and speed up your construction time. Contact us for specifications, design manuals, installation instructions and training videos. On site installation and safety training is also available. Contact Thermal Design for details at 800-255-0776.
"Ask for it by Name, Rely on it for Safety"
OSHA Steel Erection StandardOn January 18 of 2001, the new steel erection standard was published in the Federal Register. The new standard requires full fall protection for steel erectors and insulators at heights greater than 15 feet. This rule became effective July 18, 2001 (www.osha.gov). Owners, architects and upline contractors are potentially liable for compliance of workers on projects under their control (Standard 29 CFR Definitions–1926.751 "Controlling Contractor"). The Federal Registry, Vol. 66 No. 12 states that:
"A controlling contractor is an entity that has general supervisory authority over the work site such that it can correct safety and health violations itself or have others correct them."
In the past, steel erectors and insulators were exempt on buildings of 25 feet or less. The revised rule requires full fall protection greater than 15 feet in height. The consequence is that most buildings are no longer exempt from fall protection compliance. Workers are required to tie off or use alternative means of fall protection, resulting in a significant loss of productivity. The patented Simple Saver System solves this problem and dramatically increases productivity by providing passive fall protection.
The Simple Saver System® offers free OSHA compliant, alternative fall protection for new pre-engineered metal building purlin roof systems. Perimeter protection within six feet of any edge is required using safety harness and lanyard. Thermal Design has tested the system as instructed by OSHA and the system has passed the stringent test.
The complete Simple Saver System including insulation can be installed for approximately 25 cents per sq. ft. labor costs. Go to www.thermaldesign.com to review the third party time study.
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Energy Code CompliantThe Simple Saver Liner System with JM Formaldehyde-free™ fiber glass insulation easily surpasses the most stringent local, state and government code requirements by providing both low U-values and low emissivity values, stopping over 90% of all three types of heat transfer. Thermal Design has commissioned numerous hot box tests which were done in accordance with ASTM C-1363, “Standard Test Method for the Thermal Performance of Building Assemblies by Means of a Hot Box Apparatus.” Hot box tests, studies, and reports that pertain to the true effectiveness of “traditional” metal building insulation and the Simple Saver System are available upon request. Contact Thermal Design at 800-255-0776 or www.thermaldesign.com for test and technical information.
Simple Saver vs. Traditional MethodsWith today's high energy costs and the potential for continued increases, owners, designers, builders and the government are all focusing their attention on more energy efficient buildings. Improving the building envelope design and maximizing your insulation performance will return more value to the owner than any other building material going into the project. The Simple Saver System is designed to solve the defects of “traditional” compression insulating methods. Properly placing and sealing the liner system to create the full required insulation space will virtually eliminate insulation compression and assure the ultimate performance.
Performance
*Voids in Insulation
TRADITIONAL METHODS• Severely Compressed Insulation• Defective Vapor Retarder Placement• Voids in Insulation• Exposed Conductive Structure• Unfinished Appearance• Poorly Sealed Seams• Bracing Interference• Invites Condensation Problems
SIMPLE SAVER SYSTEM• Full Thickness JM Formaldehyde-free™ Fiber Glass Insulation• Proper Vapor Retarder Placement• Purlins Fully Encapsulated• Finished Appearance• Triple Extrusion Welded Seams• No Bracing Interference• Prevents Most Condensation
Simple Saver"Liner System"
Over-the-Purlin"Single/Double Layer"
Long Tab System"Filled Cavity"
Screw Down RoofsScrew down roofs can be approximately $0.50-$0.75 less expensive than a standing seam roof just considering the material cost. These savings could be invested towards the roof and wall insulation to help offset project costs and still meet today's and tomorrow's stringent code requirements.
The verified performance of the Simple Saver System installed in a screw down roof exceeds all “traditional over-the-purlin” metal building insulation assemblies currently listed in ASHRAE 90.1, IECC and COMcheck™.
Third party hot box test verify U-values as low as U-0.0203 can be achieved with the Simple Saver System installed in a screw down roof. The system will also assist in design goals to earn LEED credits, tax deductions and incentives, and meeting advanced energy efficiency standards such as California's Title 24.
LEED Contribution AreasEnergy & Atmosphere
Materials & Resources
Innovation & Design Process
Indoor Environmental Quality
Commercial Building Tax DeductionThe Simple Saver System can help owners or designers claim a tax deduction of up to $1.80 per square foot for upgrading the envelope, HVAC and lighting that result in 50% savings over the ASHRAE 90.1-2001 Standard. This incentive has recently been extended to 2013. Example: A 20,000 sq. ft. qualified building would yield a $36,000 tax deduction. Call Thermal Design for assistance with rebates and credits.
LEEDContributes points to
LEED projects!
EPA'05Energy Policy Act
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<--- Years of Ownership --->
Basic Building Cost$250,539.99*
Total Savings
1 25
Cum
ulat
ive
Val
ue o
f S
avin
gs
HVAC
Insulation
Lighting
Savings
Traditional Building
Simple Saver Synergy DesignSM
Graph is for illustrative purposes only. Additonal savings are available.
Simple Saver Synergy DesignSM
Call for a FREE Synergy Design Analysis of your upcoming project! New or Retrofit!
Ownership Savings Energy Savings Pay for Basic Buildings! Not only can energy efficient buildings be built with no added cost compared to traditional metal buildings, the owner saves monthly on energy and maintenance costs. The value of these monthly savings when compared with traditional metal buildings can pay for the building itself. Call a Synergy Design Expert to discuss potential savings for your project.
*Example calculation for a 10,000 square foot building in Nebraska. Each building is unique and results will vary. Value of savings assume a 2% average yearly increase in energy costs and investing savings at 4.7% yearly rate of return.
Initial Construction Cost for Energy Package
Insulation and Interior Finishing Super-insulate with the Simple Saver System to control heat loss and gain through the sealed building envelope. The Syseal® fabrics' bright white appearance is also used as an exposed interior finish.
HVAC Reduce HVAC equipment, installation costs and related costs such as gas piping and wiring by adjusting the design due to the superior thermal performance. Use EnergyCraft HVAC appliances to further reduce installation and other costs such as structural, roof curbs, etc.
Lighting Reduce the number of fixtures, wiring and circuit costs required to reach desired light levels. Reductions up to 30% are achieved because of the high reflectivity of the Simple Saver System. Use high-efficiency EnergyCraft plug-in luminaires to further reduce installation costs.
Incentives Take advantage of available tax incentives, loans and grants that can further reduce costs when compared with typical construction.
Energy and MaintenanceSave on energy and maintenance costs for the life of the building.
Project Cost Trade-offsIn addition to the savings in HVAC and lighting systems, the Simple Saver Synergy Design offers savings in building structure, construction safety, aesthetics, acoustics, finishes and other potential saving areas.
Potential Savings AreasThrough Fall Protection (OSHA compliant) $0.20 - $0.35 / sq. ft.
Painting/Finishing Savings (purlins & girts encapsulated) $0.25 - $0.45 / sq. ft.
Standing Seam Roof Savings $0.15 - $0.75 / sq. ft.
Mechanical Equipment Reductions & Savings $0.30 - $1.00 / sq. ft.
Lighting & Acoustic Treatment Savings $0.00 - $1.00 / sq. ft.
Downsizing Utility Service $0.00 - $1.00 / sq. ft.
Suspended Ceilings, Dry Wall Ceilings and Walls $1.50 - $3.00 / sq. ft.
It does not have to cost more to build an energy efficient building. The Simple Saver Synergy Design method reduces costly energy consuming equipment and related costs of traditional construction to pay for energy saving improvements. The result is an energy efficient building that typically does not cost more to build, but saves money for the lifetime of the building. Here is how it is done:
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Simple Saver Synergy DesignSM
EnergyCraft energy efficient heater and air conditioner (wall mounted horizontal appliance shown)
Full thicknessJM Formaldehyde-free™
fiber glass insulation
Up to 85% reflective bright white fabric liner
30% fewer light fixtures
Insulated doors and windows
Downsized utility service (gas & electric)
Standard air circulation ceiling fans
Building Cut-away of Simple Saver System® and EnergyCraft® Energy Efficient Systems
Quik-Stop™thermal break
EnergyCraft AppliancesEnergyCraft appliances are pre-fabricated, pre-wired, self contained, “Ready-to-Run” units that simply mount into place and operate when utilities are connected. A framed opening is provided by the contractor during the building erection process. These appliances are designed specifically to work with energy efficient buildings using the Simple Saver System. Thermal Design will provide a quotation for the recommended installation and guarantee the sizing of the equipment for the quoted parameters. A thermostat and cord are supplied with all units. Units may be ducted by third party.
95% high efficiency gas heaters14 & 16 SEER rated air conditionersHVAC units are designed as appliances for fast installationNo license normally required for EnergyCraft packaged unitsHeat pumps that work to 30˚ below zero5 year parts guarantee & lifetime heat exchanger warranty
Appliances are available in a variety of combinations. Choose from various options:
Fuel Source: Gas, Electric or PropaneUnit Type: Package, Split, Cool or Heat onlyOrientation: Horizontal or Vertical
EnergyCraft LuminairesEnergyCraft Octalux™ & Quintalux™ high efficiency, high bay fluorescent light fixtures are designed to lower operating costs by about 50% while providing the same amount of light when compared to traditional metal halide fixtures. The 94% efficiency, durable construction and high light output make this one of the most effective investments in your building design.
UL labeled and made in the USA4 lamp or 6 lamp fixtures available with T5 or T8 lamps6 foot cord and NEMA certified twist-lock plugCenter mounted ballast 1 year fixture and 5 year ballast warranty
Complete Nationwide Service and Distribution Available!
EnergyCraft Luminaires
Available AccessoriesCeiling Fans Lamp ProtectorsExhaust Fans Daylight SensorsIntake Louvers Occupancy SensorsVentilation Systems Control SystemsEconomizers Heat Reclaimers
EnergyCraft Wireless Management Products available soon for even more savings!
Wall Mount Horizontal Appliance Floor Mount Vertical Appliance
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Marketed by Simple Saver Services, LLC: Each company is responsible only for their respective product claims.
Guarantees, Warranties and NoticesThermal Performance Guarantee
Please visit www.thermaldesign.com for Thermal Design's Thermal Performance Guarantee.
Ten-Year Limited Materials Warranty
The Simple Saver System® has a limited warranty. Thermal Design warrants this product subject to certain conditions and exceptions. Ask the seller for a copy of the warranty. Please visit www.thermaldesign.com for full details regarding Simple Saver System's Ten-Year Limited Materials Warranty.
Notices
Specification values are typical data subject to normal manufacturing variations and are not meant to be guaranteed or limiting specifications. Thermal Design, Inc. reserves the right to improve and change component specifications without notice.
The information and performance values contained in this brochure replace and supersede all other previous documents created and managed by Thermal Design, Inc. This is largely due to recent industry studies, tests and modeling on metal building insulation assemblies and the resulting thermal performance as typically installed.
States and/or jurisdictions may have a variety of insulation regulations. Check for specific details regarding the insulation regulations that apply in your area.
Patents, Trademarks and Licenses
Unauthorized making, using or selling of this patented technology or trademarks or service marks or copyrighted works shall be each subject to a minimum royalty and lost profit per square foot of surface insulated from such unauthorized acts. Sellers of any component with the knowledge or intent that such component is to be used to evade the purchase of legitimate materials from authorized sources shall be held liable as contributory infringers and otherwise as lawful. All costs of collection, including legal fees and costs, shall be sought as damages for unauthorized use and infringement.
Simple Saver System®, Synergy Design™, Snap-R™, Stand-off 'Z' Brackets™, Quik-Stop™, Fast-R™, Syseal®, Syseal Building Wrap™, UVMAX® and EnergyCraft® are trademarks licensed to Thermal Design, Inc and Simple Saver Services, LLC. All trademarks are property of respective parties.
JM Formaldehyde-free™ fiber glass insulation manufactured by:
JM Warranty Information
The physical and chemical properties of Microlite® "L" and PEBS Blanket™ represent typical, average values obtained in accordance with accepted test methods and are subject to normal manufacturing variations. They are supplied as a technical service and are subject to change without notice. Numerical flame spread and smoke developed ratings are not intended to reflect hazards presented by this or any other materials under actual fire conditions. Check with the Regional Sales Office nearest you to assure current information. All Johns Manville products are sold subject to Johns Manville’s Limited Warranty and Limitation of Remedy. For a copy of the Johns Manville Limited Warranty and Limitation of Remedy, and information on other Johns Manville thermal insulations and systems, call 1-800-654-3103.
JM Formaldehyde-free™ fiber glass insulation, PEBS™ and Microlite® "L" are registered trademarks of Johns Manville, Denver, CO.
Simple Saver System® manufactured by:
Available through your distributor below:
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America's Leading Thermal System Technology1-800-255-0776 | Available Nationwide and Export
www.thermaldesign.com
Better Living from the Inside Out1-800-654-3103 | www.specjm.com