Many new homes are still being designed with two furnaces, one in the basement and one in the attic. Some have an attic only furnace in order to maximize living space by reducing utility room size when homes are built on slabs. Most always high efficiency condensing units are installed in attics. They cannot operate in cold attics due to condensate freezing and other issues. Thus, builders have traditionally been “semi-insulating” attics or building insulated boxes for high-efficiency furnaces. Both of these approaches severely limit the ability to get a HERS 55 or lower.
First, boxes should almost never be used. It leaves a portion of the duct system in a cold attic that has to be modeled as such. This costs HERS points. It is far better to bring the entire system inside conditioned space by making a thermal barrier and aligned air barrier along the attic roof deck and gable walls. Herein lies the challenge!
Spray foaming the roof deck is one effective approach because it creates an all-in-one thermal and air barrier that is aligned and very effective. However, this is typically most expensive and requires at the least a layer of closed cell foam to prevent moisture intrusion. More often, “net and blow” with cellulose or fiberglass is used under the roof deck as an effective thermal barrier. This can be a good approach. However, these materials do notcreate an air barrier.
In order to have an effective air barrier in an attic, it is necessary to have a continuous and complete air barrier on both sides of the blown-in insulation. Six-mil polyethylene simply does not work as an interior air barrier. Blower door testing using poly has proven this. It must be a rigid board that can be well sealed. In order to make an effective exterior air barrier, it is necessary to seal the edges of the roof-vents under the sheathing from the baffles at the eaves all the way to the ridge. The goal is to make the blown-in insulation cavities air-tight. These measures will contribute significantly to a better HERS score!
One last note is that it is important to have air barrier work prepped or done before the HVAC equipment is installed in areas where access will be blocked once it is in place.
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