HIGH EFFICIENCY BUILDING SYSTEM WITH REDUCED COSTS AND INCREASED THERMAL PERFORMANCE

Abstract

A system for constructing wood framed homes reduces the materials and labor costs for home construction while improving the thermal efficiency of the home. Conventional home design, layout and appearance are maintained.

Description

PRIORITY

The present application claims the benefit of U.S. Provisional Application Ser. No. 61/249,158, filed Oct. 6, 2009, which is herein incorporated by reference in its entirety.

THE FIELD OF THE INVENTION

The present invention relates to construction. More specifically, the present invention relates to a system for wood framed construction which reduces the costs of construction and materials used while simultaneously increasing the thermal efficiency of the building while maintaining a conventional style of building layout.

BACKGROUND

Wood framed construction of residential buildings is inefficient. There is a significant amount of wasted material, both in scrap materials as well as in unnecessary structures added to the home. Wood framed homes are also thermally inefficient. Many of these inefficiencies seem to stem from a disconnect between Architect/Designers, Estimators and Framers. The Architect/Designers focus on the look and function of a building with little focus on costs. Estimators seek to win a bid by negotiating the lowest material and labor costs, but have no input on design efficiencies. Different building and framing crews would use substantially different quantities of lumber. Estimators rarely see the plans before they were completed and the Architect/Designers were never involved with in depth estimating. Framing crews have their own ways of doing things that differed greatly.

Efforts to make more efficient homes frequently create an abundance of material waste and design inefficiencies. Many home plans designed for increased building efficiency or thermal efficiency result in a simple box home that cut as much buyer appeal as it did cost. These homes were more efficient but were undesirable.

There is a need for a system of building homes which reduces the materials used for construction while simultaneously increasing the thermal efficiency of the home. There is a need for a system for building more efficient homes which are attractive and which provide comfortable living space.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an improved system for building more efficient homes. Herein, the inventive building system is often referred to as the GreenLean system.

GreenLean is a design-built only system. It does not work on standard construction drawings. Buildings are designed to a unique set of standards. They must be designed and drafted to fit the elements of the system. The present invention:

1. Reduces material costs and increases the strength of the building.

2. Nearly eliminates framing waste and associated landfill costs and burdens.

3. Makes buildings 50% more energy efficient than the typical existing home, 35% more efficient than the 2006 International Energy Conservation Code requirements, and 20% more efficient than required for an Energy Star certification.

These and other aspects of the present invention are realized in a method and system for wood framed construction as shown and described in the following figures and related description.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention are shown and described in reference to the numbered drawings wherein:

FIGS. 1.1 through 1.5 show elevation and blueprint views of a conventional home design;

FIGS. 2.1 through 2.6 show elevation and blueprint views of a GreenLean designed home based on the conventional home of FIGS. 1.1 through 1.5;

FIGS. 3.1 through 3.11 illustrate wall design elements of the GreenLean system;

FIGS. 3.12 through 3.17 illustrate header, window and door designs of the GreenLean system;

FIGS. 4.1a and 4.1b illustrate cutting patterns for making insulated box headers from full sheets of sheathing;

FIG. 4.2 illustrates lumber savings for the example home of FIGS. 2.1 through 2.6;

FIG. 5.1 illustrates typical window sizes used in the GreenLean system;

FIGS. 6.1 and 6.2 illustrate conventional plumbing in exterior walls;

FIG. 6.3 illustrates GreenLean plumbing in exterior walls;

FIG. 6.4 illustrates conventional electrical wiring in exterior walls;

FIG. 6.5 illustrates GreenLean electrical wiring in exterior walls; and

FIG. 7.1 illustrates the costs savings of the GreenLean home of FIGS. 2.1 through 2.6.

It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention which is defined by the appended claims. The embodiments shown accomplish various aspects and objects of the invention. It is appreciated that it is not possible to clearly show each element and aspect of the invention in a single figure, and as such, multiple figures are presented to separately illustrate the various details of the invention in greater clarity. Similarly, not every embodiment need accomplish all advantages of the present invention.

DETAILED DESCRIPTION

The invention and accompanying drawings will now be discussed in reference to the numerals provided therein so as to enable one skilled in the art to practice the present invention. The drawings and descriptions are exemplary of various aspects of the invention and are not intended to narrow the scope of the appended claims.

The present invention provides for a wood framed home and building system which is:

1. Green—A design system that uses 50% less lumber without compromising strength.

2. Efficient—Buildings use 35% less energy than required by the 2006 IECC Code (International Energy Conservation Code) and use 15-20% less energy than an Energy Star home.

3. Affordable—Being able to achieve the two benefits above at a cost savings. While the present invention achieves increased efficiency at a reduced construction cost, traditional building methods spend thousands of dollars extra to accomplish the same efficiency results.

FIG. 1.1 shows an elevation view of an actual house plan from the inventor's building company. The house plan is called the “Normandy” and is first shown as it was built using conventional design and building methods. FIGS. 1.2 through 1.5 show the floor plan, main floor stud layout, floor framing plan and roof framing plan, respectively. It is then shown in FIGS. 2.1 through 2.6 as a “GreenLean Normandy” redesigned to fit the present system. FIGS. 2.1 through 2.6 shows the elevation view, main floor plan, main floor stud layout with 2×6 walls, main floor stud layout with thermal break walls, floor framing plan, and roof framing plan, respectively. It should be noted that the redesign had a few other builder specific goals not required by GreenLean. The situation is one of a good selling house plan that had footprint too large to fit some lots. The plan has been redesigned with these goals in mind:

1. Decrease the plan width from 61′-0″ wide to 60′-0″ in order to fit an 80′ wide lot with 10′ side yards.

2. Decrease the plan depth to a maximum of 45′-0″ in order to fit a 90′ deep lot with a front setback of 25′ and a rear setback of 20′.

3. Redesign the plan to the complete GreenLean system.

The original design has been built at about 20 times and the GreenLean version has been built six times. The information shown is actual results from several finished homes.

It is noted that both plans are the same square footage.

A comparison of the elevation views of FIGS. 1.1 and 2.1 shows that there has been very little change in the look of the home from the front.

The stud layouts shown in FIGS. 2.3 and 2.4 show that the common studs have been changed to 2×6's on 24″ centers, or alternatively, 2×4's on 12″ centers staggered on 2×6 top and bottom plates to create a 2″ thermal-break around the home.

In comparing the original Normandy home with the GreenLean Normandy home, it is noted that several modifications have been made to the layout to increase the thermal and materials efficiency as well as improve the usability of the living space.

The following figures and description highlight the various construction methods used in creating the GreenLean Normandy home. As specific details are shown throughout this article, it will be beneficial to refer back to the Case Study Plans to see how each of the elements fits into the overall house plans. The results that will be given herein relate specifically to the “Normandy” plans; however, several other plans that have been redesigned and built to the GreenLean system show the same or very similar results.

Design Elements of the GreenLean System

Framing Glossary:

To make sure all readers have the same understanding of terms as the GreenLean inventor, a glossary of framing terms and two diagrams is included for reference. Some industry professionals may be accustomed to different terms than those used. A careful review of the terms as outlined will avoid any confusion.

Stud—Any 2× piece of lumber in any length (2×4, 2×6, 2×8, 2×10, 2×12).

Common Stud—A typical vertical framing member. They come precut to fit 8′ and 9′ wall heights.

King Stud—A stud that is placed on the outside of a header and/or sill to secure them.

Trim Stud or Trimmer—Studs placed on the inside of King Studs to support headers.

Cripples—Short pieces of studs that support sills or fur down headers to the proper door or window height.

Top Plate—The horizontal member on the top of a wall that vertical studs are fastened to.

Bottom Plate—The horizontal member on the bottom of a wall that vertical studs are fastened to.

Header—A structural support member that spans openings wider than the space between two studs.

Sill—A horizontal stud that supports the bottom of a window

Wall Section—A wall section is a complete section of wall from end to end. Dimensioning is from the outside of the stud on wall ends making Rough Openings 1½″ narrower than the framing dimensions.

Wall Opening—A wall opening in part of a wider wall section. Dimensioning is from center of stud to center of stud making Rough Openings (R.O.) ¾″ narrower on each side than the framing dimensions.

Energy Envelope—The sides of a building around the conditioned (heated and cooled) space. This constitutes the exterior walls, ceiling with attic space above, and floors with ground below. It is basically the outside shell of a building.

Exterior Walls:

FIG. 3.1 illustrates framing for a conventional wall. Traditional framing methods generally adhere to a system of 2×4 studs 10 placed at 16″ on-center (O.C.) intervals for exterior walls. Because the studs 10 are spaced differently than roof trusses 14, a double top plate 18 is used. When extra insulation is desired or more strength is needed, 2×6 studs are used. Now that people are being more cautious about energy efficiency, 2×6 studs are becoming more popular. This helps reduce energy consumption but causes two other problems.

The added cost of the thicker studs and extra insulation is prohibitive to some Buyers. Those who have a moderate amount of money for upgrades and have to carefully pick their options will generally choose items like granite countertops, jetted tubs or stainless steel appliances over extra insulation. Builders that make 2×6 walls standard in a slow or recessed building economy risk losing sales to competition with a lower price.

Although more energy efficient, a 2×6 wall is not green. Studs that are 50% thicker require the harvest, production and shipping of 50% more trees. The advantage of energy savings comes at the cost of our precious natural resources.

FIG. 3.2 illustrates framing for a GreenLean wall. According to one aspect of the invention, the GreenLean system frames all exterior walls with 2×6 studs 22 at 24″ O.C. intervals. The studs are 50% thicker but also 50% further apart so that the total board feet of trees needed using this one element of GreenLean remains the same. Because the stud spacing matches the spacing of the trusses 26, a single top plate 30 can be used. Other techniques of the GreenLean system will show how the system dramatically decreases the board feet of lumber used in a 2×6 wall over what is required in traditional 2×4 framing. An engineering analysis has shown that the GreenLean method of using 2×6 studs at 24″ O.C. spacing is 4% stronger than traditional walls of 2×4 studs at 16″ O.C. The GreenLean wall will structurally handle heights to 10′-0″ with the roof loads for most geographic areas. This wall configuration is advantageous because it allows for the use of a single top plate instead of a double top plate, and allows for the other aspects of the GreenLean system as described below.

FIG. 3.3 illustrates framing for another GreenLean wall. According to another aspect of the invention, the GreenLean system frames all exterior walls with 2×4 studs 34 at 12″ O.C. intervals with 2×6 top plates 38 and bottom plates 42. Every other stud is attached adjacent the outside edge of the 2×6 top and bottom plates and the remaining studs are attached adjacent the inside edge of the top and bottom plates. This wall allows for insulation between each stud and one of the interior and exterior wall surfaces, eliminating a continuous heat transfer pathway through the wall via a stud. This Thermal Break wall significantly improves the insulative properties of the wall.

Exterior Dimensioning:

The GreenLean system requires the exterior walls of all buildings to be designed in 2′ increments to maximize the efficiency of the 24″ O.C. framing layout. The 12″ O.C. framing layout shown in FIG. 3.3 also allows for a layout in 2′ increments. Every wall length and jog in the exterior of the building must be in a 2′ increment. Since studs are purchased in 2′ length increments, this reduces waste.

The front and rear walls are framed first and then the side walls are set in between them. The first stud on each end of the side walls are set in 5½″ as indicated at 46 (2×6 studs are actually 1½″×5½″) to compensate for the thickness of the front and rear walls they butt up against to form corners. The second stud is centered 24″ from the outside of the adjoining front or rear wall or 18½″ in from the first stud as shown in FIG. 3.4.

FIG. 3.4 illustrates a simplified GreenLean layout to illustrate the stud placement and wall layout at corners.

Corners:

Traditional framing methods use at least 3 and as many as 5 studs in corners 50 to provide a solid backing for nailing sheetrock. Before structural engineering was required, 2 studs 54 were always placed at the end of each wall for structural support. An additional stud 54 was added as drywall backing, making a 5 stud corner. FIG. 3.5 illustrates a traditional 5 stud corner.

Engineers have now determined that only one stud 58 is needed at wall ends. Builders add another stud 58 for drywall backing. This has lead to the use of a 3 stud corner 62 in more recent years. The third stud is not structural; it is only needed for drywall backing. FIG. 3.6 illustrates a traditional 3 stud corner.

The GreenLean system uses only 2 studs 66 in corners 70 with strips 74 of 7/16″ OSB (Oriented Strand Board) used as drywall backing. This saves at least one stud and allows more space 78 for insulation. The strips of OSB may be cut from scrap material. A traditionally framed wall with a 2×4 for drywall backing leaves only 2″ for insulation. A GreenLean wall with 7/16″ OSB backing leaves 5 1/16″ for insulation. Thus, the GreenLean corner significantly reduces material usage and improves the thermal efficiency of the wall. FIG. 3.7 illustrates a GreenLean corner.

Perpendicular Walls:

In traditional framing, interior perpendicular walls that butt up against an exterior wall are attached with a three stud pocket 82. This method uses three studs 86 and leaves a section 90 in the energy envelope of the home 6½″ wide that is void of insulation. FIG. 3.8 illustrates a conventional perpendicular wall.

More recently ladder blocking is being used. With ladder blocking, horizontal blocking studs 94 are turned on end and placed between common studs 98 to resemble a ladder. This method is greener than a three stud pocket because it can save three studs if scraps are used. It allows for insulation 102 behind the blocks, even if it is only 2″ thick. It typically uses three 14½″ pieces of 2×4 studs that a careful framer can find in the scrap pile. A draw backs is that the Drywaller only has three 3½″ areas to attach to rather than the entire vertical run of the wall. FIG. 3.9 and FIG. 3.10 illustrate a wall using ladder blocking.

Perpendicular walls in GreenLean design use scrap pieces 106 of 7/16″ OSB wide enough to be attached to the end of the perpendicular wall 110 and allow drywall backing on both sides. No additional studs are used and there is 5 1/16″ for insulation. FIG. 3.11 illustrates such a perpendicular wall.

Insulated Box Headers (IBH)

As will be shown in the two sections that follow, all window and door openings in the GreenLean system fall into three opening sizes. Because only three opening widths are used and one is a 1′-10″ window which does not require a header, only two header widths are needed. IBH are pre-built at widths of 3′-10½″ and 5′-10½″ to fit all window and door openings. The IBH design will meet engineering specifications in most building areas up to 6′-0″ wide. Some high elevations with heavy snow fall are excluded.

Garage headers, which are greater than 6′ are made of engineered or dimensional lumber. Since they are not in the energy envelope or conditioned space of the home, this will not affect the energy efficiency goals of the GreenLean system.

Traditional headers are solid wood construction using 2×8, 2×10 or 2×12s with OSB sheathing sandwiched between them. Lumber in these larger sizes is more expensive per board foot than 2×4 or 2×6 lumber. 2×4 walls use 2-2×8s or wider lumber with a layer of 7/16″ OSB between them to get a 3½″ thickness to match the 2×4 wall. 2×6 walls use 3-2×8s or wider lumber with two layers of 7/16″ OSB between them to get a 5½″ thickness to match the 2×6 wall. Solid lumber construction of headers uses a significant amount of lumber and has poor insulating properties. To arrive at the desired height for the top of windows, cripples are usually needed.

In contrast, the GreenLean system constructs headers 112 of OSB sheathing 114 nailed to 2×6 top and bottom chords 118 cut down to 4½″ wide. The headers are filled with insulation 122. It is recommended to use three pieces of 1½″ thick rigid foam board to fill the 4½″ cavity. Headers are built to a height that eliminates the need for cripples. Window headers always fit into layout with no trimming of headers required. Door openings require the headers to be trimmed ¾″-1½″ when doors are placed against end walls.

Insulated box headers can be built from onsite waste material as will be demonstrated later or cut from OSB sheets with very minimal waste as shown in FIG. 4.1. FIG. 3.12 illustrates the Insulated Box Header (IBH) Design.

Windows

In traditional framing, windows are placed in walls without regard to stud location. Windows are the primary design element and framing members work around them. King studs and trimmers that support the windows are in addition to the common studs.

The GreenLean system uses custom window sizes to fit precisely within the wall framing stud layout. The wall framing is the primary element and windows are placed within their layout. Common studs 126 become king studs and trimmers 130 are added to support headers 112 for window openings.

In traditional window framing systems:

1. Windows are dimensioned without regard to stud placement

2. Headers must be cut to fit each window.

3. Hundreds of different window sizes are used.

4. Windows 6′-0″ or more wide require 2 trim studs on each side.

In the GreenLean system:

1. The windows fit perfectly between the existing common studs which become king studs when combined with two trimmers to support the windows and headers.

2. Cripple studs next to the trimmers under window sills are unnecessary and eliminated. Trimmers are split with the sill set inside of them for additional support.

3. IBH are built to a depth that eliminates the need for cripples between the top of the window and bottom of the header.

4. Since the maximum window width is less than 6′-0″, double trim studs are never needed.

5. Pre-built headers fit perfectly into openings between studs with little or no cutting.

6. GreenLean specifies trim studs be used rather than hangers attached to king studs for the following reasons:

a. IBH do not have solid ends for attachment.

b. When windows are placed side-by-side with only a single stud between them, hangers over-lap each other and windows are only 1½″ apart causing the window's nailing fins to overlap.

c. Using trim studs places side-by-side windows 4½″ apart which allows ample space for exterior finishes like brick, stucco or siding.

In order to fit precisely between the studs on a 24″ O.C. layout, there are only three window widths. There is no constraint in the system on window heights. They can be in the same increments as traditional windows. Since R.O.s are specified ½″ larger than actual window widths, the following widths fit precisely within the layout of common studs:

• • 1′10 wide window—needs no header because it fits in a 2′ or 24′″ O.C. stud spacing which has a R.O. (rough opening) of 1′-10½″.
  • 3′7 wide window—fits between a 4′ or 48″ O.C. stud opening. This requires a header with a trim stud on each side, leaving a R.O. of 3′-7½″.
  • 5′7 wide window—fits between a 6′ or 72″ O.C. stud opening. This requires a header with a trim stud on each side, leaving a R.O. of 5′-7½″.

FIG. 3.13 illustrates various GreenLean window configurations. These windows are all custom sizes that may be less available and more expensive. If this is a concern, standard sizes can be used for the 3′7″ and 5′7″ window widths as follows:

The 3′-7″ window can be replaced with a standard sized 3′-6″ wide window.

The 5′-7″ window can be replaced with a standard sized 5′-6″ wide window.

Framing is adjusted by moving one or both of the trim studs inward away from the king stud to fit the smaller window width. No additional studs are use and the small cavity between the king and trim studs is filled with Insulating Spray Foam or another insulation type.

There are some unique design constraints regarding windows that an Architect/Designer must get used to when designing to the GreenLean system. These will require changing their design style a little which may come with some resistance. Once they get accustomed to the GreenLean standards it is surprising how simple and easy it can be with very little design limitation.

Window height is not affected by the GreenLean system and any height could be used. For simplicity and inventory purposes we have narrowed the height choices to those in FIG. 4.2. The 3′7″ wide window must be 5′0″ tall to meet the building code requirement for egress in bedrooms in case of emergency. All windows must be placed at least 2′ from the end of a wall.

To design a home within the parameters of the GreenLean system and with the limited number of window sizes is an art that that will take time to master. Windows must balance on the exterior elevation of the home while being useful and attractive to the rooms on the inside, stay 2′ from end walls, and never break the 24″ O.C. layout. To accomplish this, the inventor has designed pages of window arrangement details to fit varying wall widths and room uses. A few examples are listed below; however, the comprehensive list of arrangements is not included in this article.

An 8′ wall section can use 2-1′-10″ windows side by side or 1-3′-7″ window.

A 10′ wall section can use 3-1′-10″ windows side by side or 1-5′-7″ window.

A 12′ wall section can use 4-1′-10″ windows side by side, 2-3′-7″ windows side by side, or 1-3′-7″ window with a 1′-10″ window on each side.

Note two examples of how windows can be placed “off layout” without diminishing the GreenLean system:

Example #1

A 3′-7″ window that fits into a 4′ opening doesn't fit “on layout” in a 10″ wall section because 3′ is left on each side and the 2′ O.C. layout is compromised. The 3′-7″ window can however, be placed under a 5′-10½″ header in a 6′ wall opening and the trim studs moved in from the king Studs to fit the window. Using this same example, a 4′-0″, 4′-6″, 5′-0″ or 5′-6″ window width could be used.

Example #2

A narrower window or door could be shifted under a wider header as will be shown in the door details in the next section.

Exterior Doors

The GreenLean system is designed to use the same 3′-10½″ and 5′-10½″ headers 134 as the windows use for all exterior door openings. Unlike windows, doors 138 do not need to be placed 2′ from a corner. However, it is common for exterior doors to be placed next to the end of a wall section on one or both sides. Framing dimensions begin at the outside of studs on wall ends and are dimensioned to the center of studs on the interior of walls. Therefore, a 4′ wall opening with no wall ends has an IBH width of 3′-10½″ and a R.O. of 3′-7½″ after adding trim studs; a 4′ wall section with a wall end on one side requires the IBH to be trimmed to 3′-9¾″ and has a R.O. of 3′-6¾″ after adding trim studs; and a 4′ wall section with a wall end on both sides requires the IBH to be trimmed to 3′-9″ and has a R.O. of 3′-6″ after adding trim studs. Doors are almost universally purchased pre-hung with ¾″ jams and require a R.O. 2″ wider than the door size. Side-lites can be built into pre-hung doors and typically need an additional 1½″ of jam in addition to the width of each side-lite. The same ¾″ trimming of IBH for each wall end corresponds to a 6′ wall section.

A 4′ wall section or wall opening fits these standard single-wide exterior door widths. Even though 2′-8″ wide doors are shown for those Architect/Designers that want the look of a side-lite in an entry or a narrower secondary exit door, we recommend that no exterior doors narrower than 3′-0″ be used. For doors 2′-8″ wide, one or both trim studs are moved in to get a 2′-10″ R.O. For doors 2′-8″ wide with a single side-lite, the side-lite can be 6½″-8′ wide. For doors 3′-0″ wide, one or both trim studs are moved in to get a 3′-2″ R.O. FIG. 3.14 illustrates doors and entry systems with 4′ openings.

FIG. 3.15 shows doors and entry systems using a 6′ wall section. A 6′ wall section or wall opening fits these standard single-wide exterior door widths:

3′-0″ wide—One or both trim studs are moved in to get a 3′-2″ R.O. This leaves up to 2′-5½″ to shift the door for design purposes.

3′-0″ wide with single side-lite—The side-lite can be up to 2′-4″ wide. A narrower side-lite leaves room to shift the door for design purposes.

3′-0″ wide with double side-lites—The side-lites can each be 1′-0½″ to 1′-1¼″ wide.

3′-6″ wide—One or both trim studs are moved in to get a 3′-8″ R.O. This leaves up to 2′-5½″ to shift the door for design purposes.

3′-6″ wide with single side-lite—The side-lite can be up to 1′-10″ wide. A narrower side-lite leaves room to shift the door for design purposes.

3′-6″ wide with double side-lites—The side-lites can each be 9½″ to 10¼″ wide.

Atrium Doors with one side operating—Two 2′-8″ wide doors with a 1½″ center jam require a R.O. of 5′-7½″ which fits precisely into a 6′ wall opening. These work well as a secondary exit onto a patio or deck.

French Doors with both sides operating—Two 2′-8″ doors with no center jam so that both sides operate fit precisely into a 6′ wall section. These work well in entries or as secondary exits onto a patio or deck.

Sliding Glass Doors—A sliding glass door 5′-7″ wide fits precisely into a 6′ wall opening. A 6′ wall section would require a 5′-5½″ door for an exact fit. Since sliding glass doors are made of tempered glass in preset sizes a custom size is quite expensive. We therefore recommend using only 5′-0″ wide sliding glass doors and moving the trimmers in to fit.

FIG. 3.16 illustrates doors and entry systems such as patio doors.

An 8′ wall section or wall opening fits these standard single-wide exterior door widths:

Any of the 4′ entry systems can be set “off layout” into an 8′ entry area without diminishing the GreenLean efficiencies.

Any of the 6′ entry systems can be set “off layout” into an 8′ entry area without diminishing the GreenLean efficiencies.

A 3′-0″ wide door with two 1′-10″ windows fit nicely into an 8′ wall section.

A few design notes relating to doors and windows, the differences between them, and how they can be used will be helpful:

Windows must be placed at least 2′ in from a wall end. If not the standard window widths would not fit the 5½″ narrower R.O. created by the adjoining wall. Windows must also be placed in a wall opening and not in a wall section.

Doors are different because the R.O. needed may be less than the header width. Doors may also be placed in either a wall opening or wall section. Since R.O.s are decreased by ¾″ at each end wall, a door with an end wall on each side would have a 1½″ smaller R.O. This reduces the amount of play but the door still fits. Our 3 standard window widths do not allow for this play so they are never used against an end wall.

FIG. 3.17 illustrates doors and entry systems for an 8′ wall opening.

Top Plates

Conventional framing systems place wall studs at 16″ intervals, but roof trusses are placed at 24″ O.C. Because the wall and roof members do not align, a double top plate is required to provide the structural strength to hold the roof. The GreenLean system places wall studs at 24″ O.C. which allows the wall studs and the roof members to align. With the weight of the truss bearing directly over a stud, only a single top plate is needed rather than a double top plate. A metal strap is used to connect the joints in the Top Plate for strength.

Thermal Break GreenLean Wall

The thermal break wall uses all the concepts of the standard GreenLean wall, except for the common studs. The common studs are 2×4s rather than 2×6s, placed at 12″ O.C., and staggered between 2×6 top and bottom plates as discussed relative to FIG. 3.3. This creates a 2″ thermal break of insulation (continuous insulation along the wall not interrupted by studs) around the exterior walls. This applies only to common studs, king and trim studs must still be 2×6 studs. FIG. 2.4, the GreenLean “Normandy” house plans Sheet 3a illustrates a main floor stud layout with a Thermal Break wall.

With the common studs at 12″ O.C. there are a few design parameters that can be expanded.

1. Header Widths—The system now accommodates IBH in the following widths: 2′-10½″, 3′-10½″, 4′-10½″, 5′-10½″.

2. Window Widths—The 4 IBH sizes can accommodate all the standard window widths up to 5′-6″. Simply move the trim studs in to fit even foot sizes and leave them wide to fit 6″ sizes.

3. Window Locations—There is more flexibility in window placement when being able to set them in 1′ rather than 2′ increments.

With the added flexibility in design, the Thermal Break wall is advantageous for the GreenLean system. The Thermal Break walls, however, make the system less affordable as it uses more lumber than the 2×6 walls shown and would prevent many people from using it. Since one of the three driving forces behind GreenLean is to keep it affordable, using the 2×6 wall as a basic wall and using the thermal break wall as an upgrade option for those who can afford the difference allows the system to be more fully implemented with energy savings in each application.

In extreme climates or when greater energy efficiency is desired, the Thermal Break wall can be used with 2×8 or greater top and bottom plates. The common studs are still alternated between the inside and outside sides of the top and bottom plates. The only additional cost in going to the thicker wall is the increased top and bottom plates and insulation. This is a very low cost way to achieve maximum results. The Thermal Break wall thus provides an economic way to provide walls with significantly higher insulation values without significantly increasing the lumber cost of framing the wall.

Interior Walls

The GreenLean system is designed for the exterior walls of a building. These walls encompass the energy envelope of a home or building. Interior walls are not required to fit any particular layout. Interior non-bearing walls use 2×4 studs rather than the 2×6 studs used on exterior walls. Some bearing walls or plumbing walls may require 2×6 studs. Framing interior walls can be done at 16″ or 24″ O.C. intervals without affecting the energy efficiency of the GreenLean system. To reduce material usage, GreenLean specifies 24″ O.C. intervals to reduce lumber usage.

Material Savings

Eliminating Waste

One of the best ways to save materials is to minimize or eliminate waste. Although the GreenLean system cannot completely eliminate framing waste, it does come close. Here is an explanation of the Design Elements and the waste savings of each one.

Exterior Walls—Exterior walls are designed in 2′ increments to match lumber sizing and maximize its usefulness. A wall length of 12′-4″ would require top and bottom plates of 14′ with 1′-8″ of waste. A 4″ piece of OSB would need to be cut from a 48″ wide strip. OSB sheets are used in either 2′ or 4′ widths. A 2′ width cuts a sheet of OSB exactly in half and the remaining half is always used on the opposite side. No forethought is needed on where to use odd cuts such as the 44″ wide remainder piece of OSB in this example.

Insulated Box Headers—The material needed to make IBH is taken from the sheathing cut out of doors and windows or from roof sheathing scraps. An assumption here is that doors and windows are sheeted over and the openings are cut out afterwards, but this is not necessary. It is most efficient to take 3′-10½″ IBH OSB sides from scraps in windows 4′-0″ to 5′-6″ in height. The OSB sides of 5′-10½″ IBH are taken from windows 6′-0″ or greater in height or from door openings. If enough jobsite waste is not produced to make all the required IBH, FIGS. 4.1a and 4.1b show how to maximize the use of a sheet of OSB for minimal waste.

Full sheets of OSB can be cut to form IBH with little to no waste as shown.

Corners—Drywall backing strips are cut from scrap OSB and nailed in corners. A full depth for drywall backing strips in corners is the 5½″ depth of a 2×6 plus a 1½″ nailing surface for a total of 7″. The minimum recommended backing depth is 2½″ on the stud and a 1½″ nailing surface for drywall.

Perpendicular Walls—The ideal size OSB drywall backer for a perpendicular wall is 6½″. This is the thickness of the 2×4 interior wall plus 1½″ on each side for drywall nailing.

Sheathing—After the larger remainder pieces of 7/16″ OSB are first taken for IBH, the remaining scraps are cut into drywall backing. Drywall backing does not need to be a continuous piece of OSB from top to bottom. Numerous shorter pieces down to about 12″ can be stacked to meet the wall height. It works best to set up a table saw for 6½″ cuts and use this size for both corners and perpendicular walls. Remainder pieces down to 4″ can be used in corners. This way the only sheathing scrap on a job should be pieces less than 4″×12″ in size. The only remainder pieces of 23/32 T&G floor sheathing come from cut outs for stairs. If possible, these scraps are not used for drywall backing on exterior walls because they slightly reduce the amount of insulation that can be put in the wall cavity. They are used for drywall backing on interior walls and at ceilings where insulation will not be diminished. Sheathing waste can also be used to cover the rim joists or belly-band.

Windows and Doors—Windows and doors in conventional framing use the common studs in the wall layout and four additional studs—a king and trim stud on each side of the associated header opening. Since GreenLean openings fall on the 24″ O.C. layout of common studs, the common studs on each side of an opening become king studs and only two extra studs are uses for trimmers. The trim studs are split and sills inserted from king stud to king stud to eliminate the need for cripples next to the trim studs. See FIG. 3.13.

Top Plates—One top plate is eliminated from the entire perimeter of the building. The only plate waste necessary in GreenLean is 8-5½″ pieces of 2×6 on the far left and right sides of a building. This is 4 pieces each in the top and bottom plates.

Roof Sheathing—Roof sheathing can be a major waste item on a building because angled pieces are hard to use. In the GreenLean system they can be cut into strips for drywall backing. The small spaces in backing left by angled cuts have very little effect on fastening drywall.

Floor Joists—Adding a floor joist layout to the floor framing plan can save hundreds of dollars in joist costs and almost eliminate waste. Joists can be ordered in 2′ increments at any length up to 60′. Since all GreenLean dimensions are also in 2′ increments, the only waste is the thickness of the rim joists on each end or 2½″ to 3″ per joist. Some lumber yards will measure the foundation of a building and actually precut the entire floor, eliminating all waste. Floor sheathing in the GreenLean system is also minimized. Any remainder pieces are always in 2′ increments that can be used elsewhere or moved to another job. The only waste should come from the cutouts for stairways.

Sills, Cripples, Bracing and Blocking—There will always be some waste in these areas whether conventional or Greenlean methods are employed. Remainder pieces of studs that are 22½″ long can be used for blocking. Shorter pieces can be used as cripples or squash blocks and are harder to find a place to use.

Case Study House Comparison

Now that all the design elements have been explained and you have been shown how to minimize waste, let's analyze the results of the system using the case study home.

The most surprising savings area is in the amount of lumber used. FIGS. 4.2 and 7.1 show a comparison of lumber used in the conventional Normandy home vs. the GreenLean Normandy. The square footage is exactly the same for both plans and the exterior elevations are close to identical. Notice that the conventionally designed Normandy plan uses 286 studs in the exterior envelope of the home. The basic GreenLean wall uses only 136 studs (52% less) and the Thermal Break GreenLean wall uses 224 studs (22% less). This does not even account for the savings in cripples, top plates, headers and sheathing.

Similar savings are also realized in 24″ vs. 16″ O.C. framing of interior walls; precut floor systems or a joist plan for ordering in 2′ increments; floor sheathing with virtually no waste after using stair cut out pieces for drywall backing; and roof sheathing waste also being used for drywall backing.

The most accurate comparison of lumber is to compare the board feet of lumber used. The percentage of savings using GreenLean is listed below. It is amazing how much less lumber is used for a far superior system.

GreenLean vs. Conventional 2 × 4 Normandy 17.37%
GreenLean vs. Conventional 2 × 6 Normandy 28.38%
Thermal Break vs. Conventional 2 × 4 Normandy 14.41%
Thermal Break vs. Conventional 2 × 6 Normandy 25.81%

Minimizing Material Inventories

A good way to reduce waste is to minimize the number of items used in the building process. This is especially true if you inventory your own materials. Less items means less storage space, less handling and sorting, bulk buying power for high use items, easier accounting and less cost. Production builders will benefit from these more than custom builders.

Notice from the spreadsheet in FIG. 7.1 that the GreenLean home uses far fewer types of lumber items than the conventionally designed home. Using fewer types of lumber items not only makes ordering and inventorying lumber for a house easier, but reduces the likelihood that a framer uses the incorrect materials for a task and increases the construction waste.

Walls—Most homes are designed with either 8′ or 9′ wall heights. Since both interior and exterior walls use only one top plate, precut 2×4 and 2×6 studs in 94″ or 106″ lengths are the only vertical stud sizes needed. All top and bottom plates can be specified in either 14′ or 16″ lengths. These can also be used for truss bracing and fascias. All wall and roof sheathing requirements can be filled with 7/16″ OSB.

Headers—GreenLean uses only two header sizes which are made from 2×6's and 7/16″ OSB which are already in our wall inventory. A 3′-10½″ header can be built with a single 94″ stud with only 1″ waste. A 5′-10½″ header can be cut from a single 12′ stud with only 3″ waste. This eliminates the need for large dimension studs such as 2×8s, 2×10s and 2×12s. These large dimension items use up more and larger trees and are harder to handle. Because of this they are proportionately more expensive than 2×4s or 2×6s.

Floor Systems—Try to design all buildings with one size of floor joist and modify the spacing to meet varying spans. A 23/32″ or ¾″ T&G (tongue and grove) floor sheathing rated for 24″ spans will handle all floor sheathing needs in a single item. Using only 11⅞″ joist allows plenty of flexibility in spans for design purposes.

Exterior Doors—With little effort, all homes can be designed using only 3′0″×6′8″ doors. Designers of custom homes could add a 3′6″×8′0″ size. Patio doors in GreenLean are always double 5′4″×6′8″ (double 2′8″ sets) and an 8′ height could also be added.

Windows—The inventor's building company tracked over 2,200 window sizes in their estimating software. This is quite excessive for a production builder but more common than you would think. Windows sizes in 6″ increments from 1′-0″×1-0″ to 8′-0″×6′-0″ account for 165 sizes and this doesn't account for shapes like round, half-round, quarter-round or elliptical. Many of these sizes come in Fixed Frame, Single Hung, Double Hung, Single Vent, Double Vent, or Casement styles. Then you add three or four frame colors. Next you have varying grid patterns in every size. Finally you have all these combinations three more time in standard glass, LowE glass and LowE with Argon Gas. GreenLean uses only LowE windows with Argon Gas for energy efficiency. Only 19 basic sizes are used which includes the necessary variations of Fixed Frame, Single Hung and Single Vent. It also includes Half-Round, Quarter-Round, and Eye-Leg (elliptical) sizes for design elements. These window heights and styles must also take into consideration building codes for egress from bedrooms, situations requiring tempered glass, and adding accent windows such as transoms, half rounds or quarter rounds for curb appeal. Standard windows come with white frames and no grids. If two frame colors and one grid pattern is added the number of window items jumps to 114. FIG. 5.1 shows a chart presenting GreenLean window sizes.

Labor Savings

Labor savings is a major area of study in factory production of products like automobiles and appliances. College courses are taught with formulas and methods to reduce every movement and the length of assembly lines.

In construction there have traditionally been too many variables to implement advanced production techniques. Only a few large production builders use the same people to build the exact same homes over and over. Even then there can be variations in site conditions, Architect/Designer styles, Buyers selected options, material quality or availability, weather conditions, etc. If a company masters all these variables, they are still using designs and methods inferior to GreenLean.

Framing Labor

The simplicity of building to GreenLean standards unifies framing methods. There is no adding extra waste to compensate for the methods used by different framing crews. Refer to the section on waste removal below to see how much this can vary. Every stud is shown on the plans. A framer installing 52% less studs will use far less labor. Wall layouts are much easier when everything falls on layout. A 15-20% reduction in framing costs or bids should be expected once framers are trained on the system. FIG. 7.1 shows the labor savings on the case study Normandy plans.

Estimating

An Estimator's job is easier and more accurate using GreenLean. Simple to build assemblies can make construction software faster and more accurate than ever before. For example, an exterior wall assembly in GreenLean always uses exactly 0.5 vertical studs per foot and exactly 2 additional studs for every door and window opening. No variations and no waste. Floor sheathing can always be estimated by taking the square footage and dividing by 32 (the square footage of one sheet of T&G floor sheathing). For the more advanced builders using floor sheathing layout plans; these can be eliminated. The GreenLean designs always work with no waste (other than stair wells, which gets used for drywall backing) and without time consuming sheathing layouts.

Waste Removal

The conventional Normandy built numerous times by the Inventor's home building company, usually filled a 40 yard dumpster with scrap lumber. This varied up or down depending on the framing crew used. One crew had noticeably more waste than any others used because they always used a new piece of lumber to make there cuts from rather than looking for cut or remainder pieces that would work. The first few times the redesigned GreenLean Normandy was built, a 40 yard dumpster was only about ¼ full after framing. Once trained on the system, a careful framing crew could keep waste down to about 2 yards or a few wheel barrows of waste. The average cost savings from hauling and dump fees was $400 per home. This is as much as a 95% reduction is waste.

There are four areas of savings in waste removal.

1. First are the man hours to gather it up and load it into a dumpster. If there is up to 95% less waste, there is a corresponding labor savings.

2. Second is the time to haul it to a landfill. Waste can be hauled in the bed of a standard pickup truck rather than a semi-truck hauling a dumpster.

3. Third are the landfill fees which are typically charged by weight. Here again, with up to 95% less waste, there is a corresponding weight reduction.

4. The amount of lumber purchased and used is lowered. This area has been thoroughly covered and needs no further explanation here.

Energy Efficiency

HERS Index

The HERS Index is a scoring system established by the Residential Energy Services Network (RESNET) in which a home built to the specifications of the HERS Reference Home (based on the 2006 International Energy Conservation Code) scores a HERS Index of 100, while a net zero energy home scores a HERS Index of 0. The lower a home's HERS Index, the more energy efficient it is in comparison to the HERS Reference Home. To achieve Energy Star status a home must get a HERS Index of 85. The typical GreenLean home has a HERS Index of 65 when using batt insulation and 54 when using a 1″ layer of spray foam and 4½″ blown-in insulation. Many of the GreenLean innovations are unknown not included in such rating systems. As such, many of GreenLean's notably superior energy saving techniques go unrewarded and GreenLean's true energy rating is better than shown.

Studs Cause Heat Loss

One of the inventor's driving forces in discovering the GreenLean system is the fact that studs cause heat loss. In a seminar put on by local utility companies, the inventor was shown multiple pictures with a Thermal Imaging Camera that identified significant amounts of heat loss from studs. An outline of every stud could be seen with heat loss radiating from them. Pictures were then shown of actual homes from different geographic regions that all used an excessive number of studs in wall framing. A comment was made by the presenter that it often looks like contractors are trying to use so many studs that they eliminate the need for an insulation contractor. Lumber, which has an R-Value of about 1 per inch, is a poor insulator.

Structural Engineers were consulted and it was learned that a large lumber of studs used are not needed for the structural integrity of a building. Some are only used for drywall backing and others are not needed at all.

The R-Values for batt and blown-in insulation for a 2×4 wall are generally R-13 and R-15 respectively; with the areas filled by 2×4s at only R-3.5. The R-Values for batt and blown-in insulation for a 2×6 wall are generally R-19 and R-22 respectively; with the areas filled by 2×6s at only R-5.5. In the Case Study house the Greenlean system used 52% less studs and filled this space with high R-Value insulation. The other components of GreenLean also increase energy efficiency:

Thermal Break GreenLean Wall—Studs a poor insulator, so there is a greater amount of heat transfer through them than through insulation. The Thermal Break GreenLean wall provides a 2″ thermal break to stop this heat transfer.

Corners—Corners are a more vulnerable area of energy loss because they have air forces coming at them from two directions. The conventional 3 and 5 stud corners make the problem worse. GreenLean minimizes this problem by providing a large insulation pocket in the corners and eliminating studs at corners.

Perpendicular Walls—The traditional 3-stud pocket leaves an area 6½″ wide completely void of insulation. Ladder blocking leaves only 2″ of insulation in a 2×4 wall and 4″ in a 2×6 wall. GreenLean walls have 5 1/16″ insulation at all perpendicular walls.

Top Plates—The GreenLean Normandy has 208 lineal feet of top plate. Using a single top plate replacing 26 square feet of lumber with insulation. The use of raised heels on trusses which allows a full thickness of ceiling insulation as the top and bottom chords come to a point at the eves is recommended.

Windows—GreenLean window assemblies are more energy efficient in four ways:

1. The area of two common studs and two cripples is replaced with insulation.

2. Windows, which have R-Values less than studs, are the greatest energy loss area in a wall. GreenLean windows are 5″ narrower (3′-7″ vs. 4′-0″ and 5′-7″ vs. 6′-0″) so they have over 2 square feet less area on a common 5′ tall window. The GreenLean Case Study house as 18 square feet less window area because of this size difference. Any visual difference has been undetectable by the hundreds of people touring the inventor's homes. Even Architect/Designers asked to spot the difference have not been able to do so.

3. Conventional design and framing techniques use headers of dimensional lumber over doors and windows. The GreenLean Case Study house replaces what would be 51 linear feet of R-3.5 (R-5.5 in a 2×6 wall) dimensional lumber headers with R-22.5 Insulated Box Headers.

4. GreenLean requires energy efficient LowE Argon Gas filled windows. These are some of the most energy efficient windows available.

Doors—Doors also save two studs and use IBH. The use of fiberglass exterior doors over steel or wood doors is recommended.

Plumbing—Plumbing vents and drain lines leave areas void of insulation in the energy envelope of a home or building. GreenLean runs drain lines from sinks near exterior walls through the bottom of the cabinet and through the floor joists rather than through the back of cabinets and down the wall. Studor vents replace conventional vent stacks that go up through the roof on exterior walls.

FIGS. 6.1 and 6.2 illustrate a conventional plumbing drain or vent pipe 142. Placing the pipe in an exterior wall 146 leaves a large insulation void 150, reducing the thermal efficiency of the wall.

FIG. 6.3 illustrates a GreenLean plumbing drain and vent pipe. The drain pipe 154 does not pass through the exterior wall 158, but passes out the bottom of a cabinet 162 and through the floor 166. As such, the insulation in the exterior wall is not compromised.

Air Migration

Air migration within and through walls is a significant factor in heat loss and energy efficiency. A house can have a high R-Value insulation and not be energy efficient because it is drafty. GreenLean has multiple ways it reduces air migration;

Plumbing—Air cannot migrate through and around plumbing lines in exterior walls if these lines are kept out of exterior walls as explained above. Even hot and cold supply lines are kept out of the energy envelope (exterior walls).

Electrical—Using conventional methods, holes for electrical lines are drilled in a horizontal line around most of a building to provide runs for power outlets. This provides a corridor for air migration. Air that gets into one stud cavity can easily makes its way around a building using this corridor. When batt insulation is used it often gets compressed around electrical wires. Compressing insulation reduces its value and the compressed area creates a void which aids air migration. GreenLean runs electrical lines horizontally through the floor joists and then vertically up to locations where an outlet is desired. Insulation contractors are accustomed to the code requirement of foam sealing any penetrations into the floor and ceiling and will seal these holes. Even if one of these seals is broken, air can only get into that one cavity. The inventor has not seen a cost increase in having these holes sealed. The traditional corridor for electrical lines does not get sealed and it would be an added expense to do so.

FIG. 6.4 illustrates a conventional method of running electrical wires. A wire 170 is run around most exterior walls 174 due to code requirements for electrical outlets. For simplicity in chaining electrical boxes together, the wire is run laterally around the wall as shown. The wire 170 causes insulation voids 178 that allow air migrations and compromises the wall insulation 182.

FIG. 6.5 illustrates GreenLean electrical wiring. A wire 186 is run through the floor 190 where it does not interrupt insulation and runs vertically to an electrical box 194 or switch 198 or up to a light. The wire 186 is attached to the side of the stud 202 where it does not interfere with insulation.

Insulation Type—Insulation comes in three basic types—batts, blown-in and spray foam insulation. Air migrates through batt insulation quite freely. Blown-in insulation is more restrictive to air migration, and spray foam insulation prevents air migration completely. The disadvantage to spray foam insulation is its high cost. The inventor's option for blown-in insulation in the GreenLean Normandy plan is $670 and the option for a 1″ layer of spray foam insulation and the balance in blown-in is $3,020. The option for a full 5″ of spray foam is $11,875. The GreenLean system typically utilizes one inch of spray foam and the balance blown insulation in walls.

HVAC Systems—The three underlying goals of GreenLean are construction that is “Green, Efficient, and Affordable.” Some of the money saved in materials and labor can be put towards more energy efficient furnaces and air conditioners. HVAC systems should also be designed to Manual J or similar standards, furnaces centrally located to avoid long inefficient runs, joints sealed with Mastic rather than duct tape and corners in ductwork rounded to improve air flow. Homes that are exceptionally air tight need to seriously consider a Heat Recovery Ventilator so that inside air does not become stagnant.

Cost Savings

Some of the GreenLean savings are hard to quantify. We will focus on those that are readily measurable. Shown are the quantifiable savings gained on the Case Study home. FIG. 7.1 details the costs of GreenLean framing materials and labor. The GreenLean savings are summarized below:

GreenLean vs. Conventional 2 × 4 Normandy ($1,875.78)
GreenLean vs. Conventional 2 × 6 Normandy ($2,532.73)
Thermal Break vs. Conventional 2 × 4 Normandy ($1,612.01)
Thermal Break vs. Conventional 2 × 6 Normandy ($2,268.96)

Thermal Break Wall

Because of the design efficiencies of the GreenLean system, the Thermal Break wall with staggered studs at 12″ O.C. costs less to build than a conventional 2×4 house at 16″ O.C. In the case study plans, lumber costs are $725.97 less, labor costs $486.04 less, and waste removal $400.00 less than the conventional Normandy Plan for a total savings of $1,612.01. There is no way to use batt insulation efficiently with the 2″ gap for the thermal break so blown-in insulation must be used at an additional cost of $469.28 in the case study house. This makes the Thermal Break wall $1,142.73 less to build than the conventional Normandy. It is incredible that this substantially superior wall can be built for so much less.

There are other cost savings which are more indirect and not as easy to measure.

Time—The GreenLean homes typically frame in 1-2 days less time. The inventor's construction loan savings are bout $25 per day.

Inventories—This applies mainly to those who buy and store lumber in bulk. Storage, sorting, and handling of fewer items save time and money. For those builders who purchase lumber as needed from a local lumber yard, having less items to track and account for simplifies operations.

Energy Consumption Savings—No specific information could be found from utility companies on average energy consumption per square foot of a residential dwelling. Based on the limited information that could be found, the following estimates have been derived for total natural gas and electrical usage in the case study homes.

Average combined annual energy bills in a Normandy build prior to 1990 is estimated at $2,880.

Average combined annual energy bills in a Normandy build prior to 2006 IECC specs is estimated at $2,215.

Average combined annual energy bills in a GreenLean Normandy is estimated at $1,440.

This makes a GreenLean home 50% more efficient than an average existing home and 35% more efficient than a newly built home. It's ratings, which do not account for all it's innovations, is 20% better than required to receive an Energy Star certification.

There is thus disclosed an improved method and system for wood framed construction which reduces material and labor costs while improving the energy efficiency of the home. It will be appreciated that numerous changes may be made to the present invention without departing from the scope of the claims.

Claims

1. A wood framed home comprising:

exterior walls having lengths which are in two foot increments;

exterior wall top plates and bottom plates having a width of 5.5 inches or greater; and

exterior corners having only two studs.

2. The home of claim 1, wherein the exterior walls are framed with 2×6 studs on 24 inch centers.

3. The home of claim 2, wherein the door and window headers are either 46.5 inches or 70.5 inches long.

4. The home of claim 1, wherein the exterior walls are framed with 2×4 studs on 12 inch centers with a 2×6 or larger top plate and bottom plate, and wherein every other common stud is disposed at the outer edge of the top plate and bottom plate and the remaining common studs are disposed at the inner edge of the top plate and bottom plate.

5. The home of claim 1, wherein all electrical lines disposed in exterior walls are oriented vertically along a stud.

6. The home of claim 1, wherein no plumbing pipes are disposed in exterior walls.

7. The home of claim 1, wherein the walls have a single top plate.

8. The home of claim 1, wherein there are no additional studs placed in exterior walls at perpendicular joints with interior walls.

9. The home of claim 1, wherein the door and window headers are formed as a box having insulation therein.