Insulated Wall Panel System Intallation How-To

Our Prefab Wall System’s Detailed Construction Overview

Legend: R-20 Wall

1. Insul-Wall Foam Panel 16″, 24″.

2. Pre-cut foam corner piece.

3. 1″ x 8″ lumber corner piece for outside corners.

4. 1″ x 3″ strapping nailed through to 2″ x 4″ stud and plates.

5. 2″ x 4″ framing 16″ o.c. to 24″ o.c.

6. 2″ x 6″ sills at bottom and top rough stud openings at windows and door openings.

7. 2″ x 10″ (2 each) at headers of doors, sized to suit opening.

8. 2″ x 4″ – top and bottom wall plates.

9. 2″ x 6″ – top wall plate.

10. Metal wind bracing as required.

11. 1″ x 4″ strapping at each side of window and door opening.

12. 1/2″ foam spacer between headers. 211

13. Foan fillers at edge of window and door openings. 207 or 307

14. Insul-Wall panel cut to fit under window openings.

15. 2 1/4″ x 4″ True-Wall cut to length and depth of headers.

16. Lumber nailed to 2″ x 4″ at intersecting party walls.

17. Floor rim joist.

18. 2″ x 2″ furring strip nailed to foundation.

19. True-Wall cut to cover rim joist. 2 1/4″ True-Wall

20. 1″ x 3″ nailed into rin joist.

21. Concrete foundation

Cutting Foam Infill Panels

When the measurement between the centre line of studs is less than a full width foam panel, a modification must be made to create an Infill panel which will fit the stud space properly.

  • Measure the distance from the centre line of regular length stud to edge of lip of foam panel (Dimension “A” in Fig.6(a)). This distance will represent the width from centre line of stud to centre line of stud.
  • Measure and mark (using a chalk line), dimesion “A”, on the face of the Insul-Wall panel. The panel can be cut through its entire thickness along this line.
  • On the edge running along the length of the Infill panel, measure and cut the identical edge profile of a factory cut edge.

Tool for cutting:

There are two methods of cutting the profile at edge of an Infill panel,

  1. Table saw using a plywood saw blade and reverse the blade rotation. This will prevent binding of the saw.
  2. Use a “hot wire cutter” and construct two templates to match the edge profile of the foam panel. Ask your dealer about rental of the hot wire cutter.

OVERCUT THE FOAM BY 1/16″ TO ENSURE A TIGHT FIT AGAINST THE FRAMING MEMBERS.


Cutting foam panels below windows

An Insul-Wall foam panel must be cut in length to fit under the window sill. One end of the Infill panel will overlap the bottom wall plate while the other end will butt to the underside of the window sill. This is achieved by making a straight cut through the foam panel.

When the measurement between the centre line of studs, below the window, is less than a full width foam panel, an Infill panel will be required. Follow the same techniques as shown in cutting an Infill panel. (See Cutting Foam Infill Panels)

#2 Laying out and cutting plates when walls do not overhang

If no wall overhang is desired, (as in Fig. 5(b)) it is necessary to cut the length of the wall plates shorter than the building dimensions. This is required to accommodate the thickness of foam which overlaps the framing members. Plates must be shortened by the following amounts:


7 1/2″ or 5 1/2″ THICK WALL USING 5″ INSUL-WALL
CUT 2 1/4″ OFF EACH END OF WALL PLATE


Locating windows and doors for walls which do not overhang

If window and door openings on the blue prints are dimenioned from the exterior face of the outside wall, DEDUCT the thickness of the foam which overlaps the wall plates from this dimension when measuring wall plates, to ensure proper location of openings. (See Fig. 5(a)).

Laying out and cutting plates for overhanging walls (cont’d)

When the exterior wall overhangs the floor perimeter, it is important to note other construction components will require a few simple modifications.

1. ROOF TRUSSES: When ordering the roof trusses, ADD twice the amound of the overhang to the truss SPAN.

EXAMPLE:


2 1/4″ WALL OVERHANG ADD 4 1/2″ TO SPAN OF TRUSSES

4 1/4″ WALL OVERHANG ADD 8 1/2″ TO SPAN TRUSSES


2. GABLE END TRUSS: The gable end trusses should be located on top of the exterior wall to sit directly over the load bearing wall studs. The amount that the gable end truss is set back, corresponds to the amount of exterior wall overhang. (See Fig. 4(b)) The gable end truss can then be sheathed in with the appropriate thickness of foam sheathing.

Locating windows and doors for overhanging walls

if the window and door openings on the blueprints are dimensioned from the face of the exterior wall. ADD the amount of the overhang to this dimension to ensure proper location of the openings. (See Fig. 4(a)).

Rim joist infill panels for overhanging walls

Overhanging the exterior wall will require insertion of Infill panels around the rim joist of the building. The rim joist Infill panels have precut grooves for 1×3 strapping and are available in appropriate thicknesses and widths to correspond to the amount of the wall overhang and the size of floor framing members.

Header Foam

The header foam is available in pre-cut width and thickness to match the Insul-Wall thickness or in full 4′ x 8′ sheets which may be cut to required width on site.

  • Install header foam piece against lip of Insul-Wall panel. See location “A”1 – “A”1
  • At the end of the header sill, cut the header foam to a depth to coincide with depth of the factory lip, then cut horizontally and remove the piece of foam from the header foam. Repeat this on opposite end for header pieces. See location “A”2 – “A”2
  • Install 1×3 strapping in grooves and nail into header.

AT EDGE OF DOOR AND WINDOW ASSEMBLY, A 1×4 STRAPPING IS INSTALLED INSTEAD OF 1×3 STRAPPING.


Electrical Entrance

The location of the electrical entrance should be determined before starting to frame the exterior walls. The Insul-Wall panel at this location will require a slight modification to provide solid backing for the mounting of the electrical mast, The cutting of the Insul-Wall panel should be carried out before installing the panel into the wall.

Cutting the Foam Panel

The face of the Insul-Wall panel must be cut to suit the plywood thickness (5/8″). This may be accoumplished with a handsaw using the lip of the 1×3 groove as a thickness guide.

Interior partition blocking

When framing the exterior walls, it is unnecessary to install blocking for the interior partitions. This is accomplished once the walls are standing in position as shown in Fig. 9. Using this construction method, you maintain the continuity of the insulation in the exterior wall and provide sufficient backing for the fastening of the drywall finish to the exterior wall.

Cut scrap lumber to suit the measurement between inside face of wall studs. Butt nail through studs into the boards, spacing of boards to suit builder’s preference.

Construction of walls over 8’0″ in height

The Insul-Wall building system can be easily adapted to suit various wall heights. Cut a full length foam panel to suit the additional height requirements. The two panels are joined by using a shiplap joint.

Framing the walls

The Insul-Wall building system, is designed around standard wood framing practices. However, a few modifications are necessary to ensure the foam components fit properly and are tight against the framing members.

Installing corner assemblies, door and window assemblies and wall plates

It is recommended that the wall be constructed on the floor deck and then raised upright into position.

1. Cut wall plates to proper length.

2. Attach corner framing member at opposite ends of wall plates; the 3 piece corner assembly at one end and a single wall stud at the other end. Using a carpenter’s square, ensure that the corner posts and wall plates are square to each other.

3. On the wall plates, measure and mark the location of the window and door assemblies.

4. At the appropriate locations, install the prebuilt window and door assemblies. These assemblies should only be temporarily nailed to the wall plates.

Constructing the corners

Varying methods of corner construction are practised, however, Insul-Wall’s pre-cut foam corner pieces are designed to fit around the corner assemblies which are shown.

NOTE: OUTSIDE CORNER

If one wall plate start and/or ends with a 3 piece corner assembly, the intersecting wall plate will start and/or end with a single stud.

Layout and cutting of wall plates

There are two methods of construction of the exterior wall:

1. The wall overhanging the perimeter of the floor.

2. The wall flush with the perimeter of the floor.

Once the construction method has been determined, select the appropriate method of laying out and cutting of the wall plates.

#1 Layout and cutting of wall plates for overhanging walls

Overhanging the exterior wall provides an excellent method of insulation around the rim joist reducing areas of draft and heat loss.

If the wall plates are cut to the same dimensions as the subfloor, the exterior wall will automatically overhang the perimeter of the floor as detailed below. However, the amount of overhang may vary according to the builder’s preference. The wall plate length must be adjusted to coincide with the desired amount of overhang.


5 1/2″ THICK WALL USING 5″ THICK INSUL-WALL
2 1/4″ EXTERIOR WALL OVERHANG

7 1/2″ THICK WALL USING 7″ THICK INSUL-WALL
2 1/4″ EXTERIOR WALL OVERHANG


Construction of window and door assemblies

Construction time can be reduced by pre-assembling all the window and door assemblies before commencing the wall framing.

  • Determine appropriate size of header material.
  • Cut jack studs to length. Note that the jack stud should be to the underside of window or door header.
  • Fasten jack stud to regular lenght stud.
  • Cut header material to proper length. The header material length will be the total width of the rough stud opening (R.S.O.) of the window or door plus the thickness of two jack studs.
  • Cut window and door header sills and window sills to proper length. The window and header sills will correspond to the R.S.O. given in the window and door schedule.
  • Assemble the header material with the window or door header sills shown in diagram.
  • Fasten jack stud assembly to header assembly and nail as required.
  • Fasten window sill in proper location to suit R.S.O. by toe nailing through the sill into the jack stud assembly.

THE CRIPPLE STUDS WHICH ARE BELOW THE WINDOW SILL CAN BE CUT TO THEIR PROPER LENGTH, HOWEVER, INSTALLING THEM WILL BE CARRIED OUT LATER, WHEN FRAMING THE WALL.


Section “A”

Option: An alternate method of construction of jack stud assembly is shown. This provides additional lumber for fastening of window and doors.
See Fig. 2(a) and 2(b)

Installing wall studs and Insul-Wall foam panels

1. Starting at the 3 piece corner assembly, install a full width panel tightly against the corner assembly.

2. Place a wall stud against the Insul-Wall panel. Toe nail through the wall stud into wall plates. This will ensure a snug fit against the side of the Insul-Wall foam panel. Then, a nail through the wall plates into the end of the wall stud.

3. Repeat procedure 1 and 2 until a door or window assembly is reached or until a full width foam panel cannot be installed againts the window or door assembly. If the space between the last wall stud and window or door assembly is less than a full width Insul-Wall panel, an Infill foam panel will be required. However, if the space is small, the wall stud can be eliminated and the window or door assembly may be moved slightly to butt against the foam panel. (For details, see Fig. 6(a), Cutting Foam Infill Panels.)

4. Complete the nailing of the window or door assembly to the wall plates. On the opposite side of the door or window assembly, continue installing full width Insul-Wall panels and wall studs.

5. Insert the foam panel for the electrical entrance which has been modified to accept the plywood backung. ( See details Fig. 8 )

6. Under the window assembly, install full width Insul-Wall panel and cripple studs in the same technique used for installation of the full width foam panel and full lenght wall studs. (See Fig. 6(c) – Cutting Infill Panels Below Windows)

7. To complete the wall, an Infill panel will be required to fit against the single corner assembly.

Installing infill panels, header insulation, filler corner foam pieces, 1×3 strapping and corner boards

1. Determine the size of the Infill panels by measuring from the edge if the last full width Insul-Wall panel lip, (which overlaps to the centre of the wall stud) to the centre of the full length stud in the door, window or corner assemblies. Note: Full width panels and Infill panels run from centre of stud to centre of following stud. 2. The width of the Infill panels required under the window still is determined using the same technique as described in item 1.

3. The length of the Infill panels required under the window sill is determined by the length of the cripple studs. (See Cutting Of Infill Panels Below Windows, Fig. 6(c)).