Well for all of you that have been waiting for the fix of my Bulging, noisy, Thermocore walls, so are we!!!!!! Other companies have inspected our house, and feel that the "spooning" of the walls, and the noise generated by the walls could only be from when the walls were fabricated. The conditions for the foam might not have been correct.

  So, now we must build walls to support our Thermocore walls!! And wear ear plugs

I hate to hear this. I was considering using Thermocore pu walls. Are they not standing behind their product?

Here we go again... PU Foam can be very unpredictable batch to batch especially when combined with OSB.

Composite walls should be constructed by pro's and installed by pro's, both are scarce now but rest assured that the industry is changing fast and these problems will be rare in the future.

Look for panel systems that are have EPS cores, are reinforced Concrete faced and 6 inches thick when 8 Feet in height, 8 inches thick when 10 feet.

StyroHomeNews Blog

Ergodesk,
"Here we go again... PU Foam can be very unpredictable batch to batch especially when combined with OSB."
I do not have an axe to grind and no rooster or dog in this fight; I have used PU and EPS since 1974 - they both have their place. BUT, what does OSB have to do with the correct mixture, temperature (it is an exothermic reaction - isn't it?) or anything else?
Please let me know as I have only had experience with PU in metal SIPs.
Thanks,
Richm

All I want to say on this subject is that pu Foam is very difficult to produce constant consistently . The chances that every panel would have consistent foam is a "Crap-Shoot", there are dozens of factors that manufactures of Panels need to address on every panel they produce. PU Foam that is not consistent in density can shrink and cause panels to warp or Spoon in or out. OSB Skins only magnify the problems when placed in extreme temperatures. EPS Foam does not show any of the same problems, my knowledge is from over 40 years hands-on experience, hence hence here we go again.

StyroHomeNews Blog

I'm always happy to supply any "Quality Negative Reinforcement" required.

StyroHomeNews Blog

I just gotta throw this on the wall and see if it sticks... Is it possible(?) that there is a moisture/drainage problem on one side of the panel or the other? If one side of the panel has a significant amount of moisture absorbed into the OSB would it not swell at least some? The side with the higher moisture content might "grow" while the other remains the original size thus forcing the panel to bow. I suspect it would act just like a bi-metal spring in a mechanical thermostat. Can you check the drainage planes on the exterior and look for installation defects or evidence that moisture is getting into the OSB? I only suggest this because humidity tends to fluctuate significantly between summer and winter just as the temperature does. I would prefer this be the case because it is an easier fix for you. If this is the case, the panels are not the cause of problem. The installer is.

Not-So... I have been in the PU Biz for over 30 years, mfg. freezer and cooler, Transport Refer components, High end Planters for commercial properties, Advertising Plaques, and yes even Sip's including Arched Sip's, etc. etc. We need to talk more. StyroHomeNews Blog

This is just fear and smear. There is a legion of PU producers out here and you just sit back and grapeshot them all with the general claim that they are hard to make and therefore any prospective customer is taking his chances.

Every manufacturing process has some difficulties and MOST manufacturers are in business because they have developed a procedure to overcome the difficulties. Airplanes, computers and cakes are all difficult to make consistently, yet somehow we all survive Boeing, Intel and Betty Crocker on a daily basis.

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I was't aware that Boeing, Intel and Betty Crocker were making Sip's.

The only way to produce a better PU Sip is to use cured PU board stock, liquid injected PU Foam that most Mfg's use can cause the many problems that we see always popping up here on the forums. If the problems are not visible now they surly will be there eventually. Quality Negative Reinforcement

StyroHomeNews Blog

Ergodesk;

I agree with the cured PU board stock and the same is true for EPS sips, Our EPS core is oven cured for 2 days eliminating any excessive moisture content, then the  core splices are finger jointed.

Isn't your supplier SipsSupply or Commercial SipsSupply? If so, would these comments regarding PU apply to their products too?

Good Lord no!

My supplier is SIP Supply Inc. (Florida)...EPS core steel SIPS SipSupplyInc.com



......... the other is SIP Supply llc  (georgia) I think they mainly deal in PU I do not know ther process laminated or injection

Thanks. I'll bet these companies get confused frequently. The panel you use looks like something for building a metal building. Are the exteriors of the panels always grooved? Is there an exterior surface available from your supplier that you could apply an EIFS or stucco-type product to directly? I understanding that you fur the interior to put in electrical, etc. can you get an interior finish on the sip that would avoid finish work on a cathedral ceiling? As I understand it, the pros for the metal sip are strength, light weight, no mold or insect risk, long spans, and fire resistance. Is there anything else?

http://www.facebook.com/editphoto.php?aid=9721#/album.php?aid=9721&id=1834485398


Just got done installing ab 6"X6"X10 ft. cedar post on the outside of the kitchen wall, hoping that it well keep the wall from bulging out too much. It already started since the days are in the 50's . the other walls............. I do not know what to do...


The gap closed up for now. I think I need to build new inside wall all the way around the house.

 

Although it looks like Thermocore is not a Structural Insulated Panel Association (SIPA) member, (part of the problem?) I've sent a request to them asking that they contact a Thermocore decision maker and urge them to provide relief for this homeowner. I ask all SIPA members to do the same. Power in numbers right? Anyone have a contact at BASF???

We have been enjoying great successes promoting the SIP industry and should not allow this one piss poor situation to fester into bad press for the whole industry. Please help this homeowner find relief. Kevin: If you have not done so already, contact SIPA, explain the situation and politely ask for their help. Understand that they probably cannot do anything to help, but they will have it recorded in the event this manufacturer decides to apply for association membership. If there are any homeowners considering SIP's, please be wise and choose a reputable SIPA manufacturer and if possible. a SIPA builder as well. You are not likely to experience anything like Kevin.

John
PanelStar Custom Homes

Hugh;

yes they do get confused,


it is a metal panel, available with a slight groove or smooth.
Interiors are furred out with 1-1/2 steel hi-hat.
We have done direct application sythetic stucco to the panels , but I don't care for the look and you only save about 50 cents per square foot as opposed to real stucco.

other metal panel bennefits are:

no splines, no spline /joint fasteners, no cranes, soffit/facia is already prefinished,  will not swell, split, warp, better insurance rates, FEMA recommended, higher R value

for economy....Simple gable and hip roof do not require a finished roof

Also sent an e-mail to [email protected] explaining the bad press they are receiving and that it reflects negatively on the entire SIP industry. I asked them to find a solution for this customer. All interested parties reading this should do the same. Presure Thermocore to demonstrate to the customer exactly "How/Why" this is an installation problem. If they cannot, they should repair the structure.

Again, power in numbers...

John
PanelStar Custom Homes

Do they come furred from the factory? What is the cost of the finished panels compared to other skins? Would the roof look like a standing seam metal roof? Does it come in colors?