BAIHP Partnership with
Palm Harbor Homes - Corporate
Addison, TX

A Palm Harbor Energy Star home manufactured in Plant City, Florida.

First under the Energy Efficient Industrialized Housing Program (EEIH) and now under BAIHP, FSEC collaborates with Palm Harbor Homes (PHH) offering building science advice, energy ratings, and conducting diagnostic testing including infrared building and duct air tightness thermal imaging camera inspection. As a result, PHH now incorporates added return air transfer ducts to minimize pressure imbalances in the conditioned space and measures leakage of every duct system to ensure losses below 3% (Qn total) at every factory.

FSEC provided assistance to Bert Kessler (PHH VP of Engineering) with submission of an NAHB nomination for the 2004 Energy Value Housing Award.

Palm Harbor Homes: HUD-Code ENERGY STAR Testing/Research 2007

BAIHP continues to provide technical assistance to Palm Harbor Homes under cost shared funding to certify their HUD code ENERGY STAR Homes and modular ENERGY STAR homes. We provided assistance to HWC Engineering (PHH 3rd party inspector) with incorporation of Thermal Bypass Checklist and reviewing possible use of new RESNET approved sampling protocol. In addition, we compiled and submitted several product improvement ideas for the 2008 model year for Plant City plant and prepared Green recommendations for “Green Ready” PHH modular homes, which would have most of the FGBC requirements installed in the factory.

Energy Star Plant Certification for Palm Harbor Factories nationwide

With FSEC guidance, PHH Plant City produced the world's first two HUD-code Energy Star homes in 1997 (Figure above). Since then, EPA has implemented an Energy Star factory certification procedure which involves testing in both the factory and at the home sites. The procedure verifies consistent factory production of Energy Star level manufactured homes.

Nine Palm Harbor factories have completed certification (Table below) under the new Energy Star guidelines for manufactured homes.

Energy Star Ratings using EnergyGauge USA

In the fifth budget period, FSEC rated two PHH modular homes produced in Texas. Prior to that, FSEC staff conducted several Energy Gauge ratings and related energy analyses for PHH Plant City (FL) and performed two energy analyses comparing standard HUD code specifications to PHH energy improved homes sited in Detroit, Morgantown (WV), and Missoula (MT).

EnerGMiser Energy Management System

Researchers conducted an analysis of the PHH EnerGMiser Energy Management System and quantified the energy savings over base-case HUD code homes in 40+ US cities. Energy savings ranged from 28% to 42%. The results of these analyses are listed at the PHH corporate web site at www.palmharbor.com/our_homes/home_features/energy_management_system.

Factory in Albemarle, North Carolina

FSEC contacted the North Carolina engineering manager for information on Palm Harbor's typical model construction specifications in order to begin Energy Star qualifying procedures. Two PHH model analyses for three different climate zones were run to assess initial energy efficiency. These tests were rerun once specific window SHGCs were received from PHH.

On February 24 and 25, 2003, FSEC conducted a plant visit to direct and oversee Energy Star certification tests on six floor models. Tests were completed by FSEC and by factory personnel with FSEC oversight. All models passed the 3% leakage limit. To complete the certification, three additional site installed homes will be tested for compliance.

FSEC staff also worked with the plant engineer on builder option packages (BOPs) versus software options as a means to qualify homes for Energy Star. It was determined that qualifying homes in Energy Star zones 3 and 4 will be feasible using BOPs, but EG USA will be needed to certify at least some of the zone 2 homes.

Factory in Austin, Texas

PHH initiated certification procedures for Energy Star per the EPA/MHRA guidelines. Staff completed the reporting and certification on two PHH Austin homes in the Houston area for Energy Star compliance. One home passed and the other failed due to belly board installation problems. (Figures below) These belly board problems have since been addressed and the Austin plant and the remaining three Texas plants are currently being certified for Energy Star production.

Factory in Plant City, Florida

Energy Star Plant Certification

Researchers initiated certification procedures for Energy Star per the EPA/MHRA guidelines. FSEC reviewed the Design Approval Inspection Agency (DAPIA) packages and design procedures. The PHH Plant City factory was certified in February 2003 and registered one Energy Star home in Polk County, Florida.

FSEC met with the plant engineer on September 16 and 17, 2002 to analyze several new models for Energy Star eligibility. The analysis was conducted using EG USA software (v-1.32). Researchers assisted the plant engineer with a combination of EG USA software and BOPs, so that all plant models over several states could reach Energy Star levels.

Insider Heat Pumps

In 2001, five model homes at PHH-Plant City were tested for return air performance. Two of the homes were modular with Insider heat pumps. Performance results and recommendations were submitted to the plant engineer.

Staff retested two modular homes with Insider heat pumps and determined that leakage in the condenser fan compartment was depressurizing the homes. Further testing on other Insider installations is needed to uncover the scope of this problem and plans are in progress to find the best corrective course of action. BAIHP will visit PHH Plant City and observe the installation when the next Insider heat pump is requested. Researchers will look for installation problem areas and perform additional home tests.

Technical Assistance

Diagnostic tests were conducted in 2002 and 2004 on home s in Odessa and Plant City , Florida manufactured by PHH-Plant City. Th ese visit w ere requested by PHH after they received a homeowner high-utility bill complaint s . In Odessa, i nspections with the infrared (IR) camera found no insulation problems and duct blaster and blower door tests revealed airtight duct and envelope systems. Other than an oversized air conditioning system, there were no obvious reasons for the high bills. The homeowner was satisfied with the investigation and apologized for their written complaint. In Plant City, problems with the sizing of the field-installed A/C ducting had caused temperature differences in the home. PHH redid the ducting and BAIHP hasn’t heard further complaints.

Building America Homes

Palm Harbor Plant City built two homes that meet or exceeded current Building America energy goals, one study home used in the Manufactured Housing Indoor Air Quality (IAQ) study detailed in Section III, and a high visibility modular home built for the 2005 International Builders Show (IBS) in Orlando FL. Both homes were built in cooperation with BAIHP researchers. The IAQ house’s HERS score was 91.1, the IBS building scored a 93. The IAQ home demonstrated a 50% saving in A/C energy compared to an Energy Star rated home (HERS of 86.5) used for control in the same experiment. The IBS showhouse is detailed in the Technical Assistance section under “International Builders Show Showhouses.”

Factory in Sabina, Georgia

PHH signed an Energy Star Partnership Agreement to begin certification of the Sabina Plant. Two model home plans were analyzed, each with a gas furnace and a heat pump, using EnergyGauge USA software. The plant certification visit and site-installed home ratings were done in Spring 2002 and certification paperwork was forwarded to the EPA for plant registration. PHH is planning a 54-unit development in Wilmington, Ohio. Modifications made at the Sabina Plant should be very helpful for the Wilmington endeavor.

For More Information

• Case Study: Palm Harbor Homes - 16 Factories in 8 States
• Palm Harbor Homes Website