Feature: Mainstream Green

If custom builder J.D. Holt represented a critical mass of your customer base, your inventory would likely be quite different than it is right now. Though you'd still stock lumber and panels, windows and doors, siding, millwork, house-wrap, insulation, cabinets, flooring, decking, and other building materials, if you expected to sell the products they'd have to meet (and you'd have to document) a high standard for their environmental impacts. It also would help to know more than a little about their green qualities and how, combined, they create a sustainable, healthy, and energy-efficient structure.

For now, though, Holt is in the minority. The Austin, Texas, builder's goal is to deliver homes that achieve the highest rating possible (five stars) according to the Austin Green Building Program, which he did with his own 1,600-square-foot house in 2004. Only a dozen other homes in Austin have earned enough points from the 132-item checklist to achieve that standard since the program evolved to a five-star rating system in 2002, though six more eyeing that prize have been started already this year by Holt and other builders.

Credit: Charlie Brown/www.charliebrownphoto.com

And though Holt and the relatively few builders like him are on the leading edge of sustainable building, the rest of the industry is closing in fast. Austin's program alone counts 200 or so active participants and gains eight to 10 more through orientation meetings every six weeks. Meanwhile, the NAHB Research Center is currently tracking more than 30 local green building programs in 20 states, from Hawaii to Wisconsin, a number expected to increase as the NAHB's own set of green building guidelines, released last year, continues to inspire other markets to follow suit.

On a similar scale, the supply chain also has taken notice. Fifty-five of the dealers listed in the 2006 PROSALES 100 survey and ranking of the nation's top construction suppliers reported selling (if not stocking) lumber certified by the Forest Stewardship Council (FSC) or the Sustainable Forestry Initiative (SFI) in 2005 (see page 74).

Most full-service dealers already have a healthy mix of products that are essential to sustainable construction, if not yet entirely up to green standards, but they don't—or aren't aware they can—promote it. The four local building materials suppliers Holt relied on for his five-star-rated house “had common materials, like composite decking, engineered lumber and wood flooring, and fiber-cement siding,” he says, “but they weren't very informed [about chemical composition, certification, or chain of custody issues] nor did they stock specific materials as green products.”

In other words, a dual-pane, low-E window is sold as a casement or hung unit, not as a green spec, and plated roof trusses are simply an alternative to stick-framed roofs, ignoring their more efficient use of lumber and lack of construction waste by comparison.

All that is poised to change, however, as several related yet still mostly separate forces inch closer together to drive significantly greater demand for green products and building materials that reduce energy use, conserve natural resources, reduce pollutants, and deliver healthier indoor air. “Standards, guidelines, and product development [for sustainable construction] are leveraging each other,” says James Hackler, program manager for the Leadership in Energy and Environmental Design (LEED) standards established by the U.S. Green Building Council (USGBC) in Washington, such as extra points awarded to Austin green builders who use products rated by the federal Energy Star program. “There may not be one [national] standard, but they are all moving toward the same goals of better-built and sustainable housing.”

Consider the Energy Star program, which promotes the use of energy-efficient products and building methods. Launched in 1992 by the U.S. Department of Energy, Energy Star now qualifies and labels more than 13,000 models represented by 1,200-plus manufacturers of appliances, lighting, HVAC equipment, windows and doors, and other products that exceed the minimum model energy codes; Energy Star's home-certification program has exploded from a scant 55 dwellings in 1996 to a total of 400,000 homes as of last year. The program's leadership predicts that by 2012 about 1 million new homes annually, a market share of 60 percent, will be built to its standards.

Then there's the USGBC's new LEED for Homes program. Spun off from the successful LEED certification standards for non-residential buildings, the housing component is currently under a one-year pilot review process; within six months of announcing the nationwide pilot phase last summer, LEED for Homes had registered 76 builders representing nearly 350 housing units.

Meanwhile, the American Lung Association's Health House program, which sets strict standards for reducing pollutant sources and delivering high-quality indoor air, estimates that about 2,000 homes have earned its Health House distinction since the inception of the program in 1993; last year, the Health House evolved to an even higher standard and started registering builders and entire communities, including some in development by Fort Worth, Texas–based D.R. Horton, the nation's largest home builder.

Several other nationwide public and private programs and initiatives, such as Building America, Zero-Energy House, Million Solar Roofs, and Scientific Certification Systems, peck at the issue from the periphery of both the supply and demand sides, as well.

And don't discount the impact of the 35-plus local green building councils already operating, a few of which have launched since the release of NAHB's guidelines, with the prospect of more coming on line. Nearly 50,000 homes nationwide have qualified under local green building standards similar to Austin's in scope, content, and certification requirements since the turn of the century; the Built Green program for Seattle alone has certified more than 6,000 homes since its foundation six years ago.

This convergence means that J.D. Holt isn't so alone after all in his pursuit to build sustainable homes. And while his approach to building his own home to achieve a five-star rating under the Austin Green Building program is appropriately market- and climate-specific (as all such guidelines should be), his checklist provides specific insight into the types and performance of products and materials that dealers should take to heart, or at least set on a burner to simmer until that critical mass comes along.

Credit: Charlie Brown/www.charliebrownphoto.com

To get the five-star rating for his house, Holt needed a minimum of 180 points, as calculated by the value attached to 132 green building options among six main categories listed in the Austin Green Building program guidelines. He got 204 points. Here's how.

Basic Requirements. Every house that seeks certification under the Austin program must fulfill 16 basic requirements, among which there are few options. In addition to meeting the 2000 International Residential Code and the 2001 International Energy Conservation Code (IECC), the house must employ cooling equipment with a minimum 13-SEER rating (among other cooling system standards), pleated media filters for the HVAC system, at least two indoor ceiling fans, low-VOC interior paints and coatings, and either an Energy Star–rated dishwasher or no such appliance at all; it also cannot have a vapor barrier installed on the inside face of the exterior walls or any unvented natural gas logs, fireplaces, or heating units.

Per the IECC, insulation must be properly installed (read: uncompressed in the cavities); the windows must be rated for a solar heat gain coefficient (SHGC) of 0.40 or less (either in their glazing or with screens); the ductwork must be sealed, insulated, and balanced; and all recessed lighting fixtures must be air-tight and insulated.

While typical pro-oriented dealers may not even stock most of the products or materials on the required list, much less their “greened” upgrades, and certainly have nominal influence over their proper installation or code compliance, such measures create a solid foundation for the categories and specifications that follow.

Energy. Energy efficiency is arguably the most mature category within green building guidelines, having evolved from the 1970s oil crisis to include a host of product choices and design options. In Austin, the energy category offers 47 line items alone; for Holt, the category earned him 92 of his total points. “I emphatically push for about six to 10 [items] that I think make good sense to achieve the energy savings criteria,” he says, including a thicker, better-insulated thermal shell, minimum 24-inch-deep roof overhangs that enable passive cooling, and placing the HVAC system (including ductwork) in conditioned space.

Among the choices in the energy category, each with a point value and most done in combination (at least for Holt's house), the ones most relevant to a modern-day dealer include dual-paned, low-E windows that meet the SHGC standard; cool roofing materials such as tile or metal (Holt chose the latter); “total fill” insulation, such as damp-blown cellulose or sprayed foam; insulated window and door headers; continuous ridge and soffit vents; ceiling fans for all main rooms and bedrooms; and a roof radiant barrier.

Testing. This category requires builders to test the home for air leakage through the envelope and ducts, confirm a minimum level of supply air flow, and prove measures for controlling combustion gases. Holt passed the four-test trial with flying colors, collecting all 14 points available in the category.

Materials. Here's where dealers can really sink their teeth into the guidelines, though they might be a bit discouraged (or perhaps enlightened) to learn that Holt, for one, bypassed the option of combining several structural components in favor of structural insulated panels (SIPs). “If I would have gone with a standard-framed house ... I think it would have been more difficult to get finger-jointed studs,” he says, naming one of the framing component options offered. That's because, in part, he knew of only a few local sources for the alternative wall studs.

Holt purchased his SIPs package for the roof and walls of his home directly from a manufacturer. Had he chosen a more conventional system, he would have been required to specify not only the finger-jointed studs, but also at least half of his lumber and plywood as FSC-certified material. In addition, he would have been unable to use 2x10 or larger-dimension sawn lumber for the roof or floor frame (replaced instead by I-joists and engineered beams), and would have had to employ some sort of advanced framing technique, such as Optimum Value Engineering or 24-inch on-center framing, to earn not only points, but also to achieve the tight shell he needed to maintain his desired energy rating.

Credit: Charlie Brown/www.charliebrownphoto.com

Among Holt's other material choices were a composite decking material, engineered interior trim, and bamboo and cork flooring finishes throughout the house. What little lumber he did need to supplement the SIPs system he bought as recycled stock from a local Habitat for Humanity ReStore outlet.

Had he elected to also earn points for interior doors and cabinets, Holt would have been looking for sources, ideally local, that could supply those products featuring wood that was reused, FSC-certified, or from a local timber species.

Water. Among the 17 choices afforded Austin green builders in this category, few concern dealers that have turned their focus to LBM and millwork products and allowed specialty outlets and big box home centers to fill the void. “Most of the old lumberyards have narrowed their focus and have limited stock, if also lower prices,” says Holt, who sourced LBM products from a local 84 Lumber operation and The Home Depot, and other products from local specialty shops and directly over the Internet. “The DIY building supply houses had more range and tended to stock, rather than special-order, green-qualified products.”

84 Lumber's Austin location focuses mostly on lumber, doors, and windows, but is ready (within that scope) to supply the products green builders need. “Those looking to build green have done their homework and know what they need [to comply],” says sales associate Tim McPherron. “The questions we get are ‘Can you get it?' and ‘How long will it take?'”

For pro dealers delving in major appliances and plumbing fixtures, the Austin program guidelines require dishwashers that use less than 7 gallons of water per load or are Energy Star–qualified, while toilets must meet a local water utility's standard for water use. The category also awards points for on-demand hot water recirculation systems and gutter systems that effectively direct rainwater away from the home's foundation.

Health & Safety. For the most part, this category's six subsections and 25 overall specification options focus on indoor air quality, humidity control, and pest management—areas that typically bypass what an LBM dealer stocks ... until you take a closer look. For example, the category includes construction adhesives and paints, both of which must contain no volatile organic compounds (VOCs) or must be be low-VOC to earn points for the builder. Insulation, meanwhile, must be formaldehyde free, as do the structural and finish components of the cabinets. For pest control, wood framing up to 3 feet from grade must be treated with borates or substituted for a non-wood alternative, among other options.

As further evidence that green building as a concept is also about improving comfort and livability around the home, Austin green builders can earn a point each for installing lever handles (rather than knobs) on doors, and grab bars and anti-scald devices in tubs and showers, as part of an aging-in-place subcategory—presenting another opportunity (albeit small) for dealers to help their green-minded builders make the grade.

Community. The Austin program's final category for compliance deals with quality-of-life issues and stemming urban sprawl, awarding points for features such as a covered front porch of at least 100 square feet, a home office with a dedicated entry, the use of water-pervious driveway and walkway materials, and down-lit exterior light fixtures, among other line items. A savvy dealer can find sales opportunities in all of these examples, whether the yard keeps the products in stock or knows where and how to source them quickly and affordably. “Part of our job is to offer choices and options to our customers to earn points [for green building],” says McPherron, such as composite decking instead of treated lumber for those porch points.

When it was all over, Holt had checked off 86 of the 132 available options listed in the Austin Green Building program guidelines, not counting the 16 basic requirements, to achieve his 204 total points and a five-star rating for his house. “I've totally committed my company to the green building philosophy, and I encourage my clients to use the same philosophy,” he says. “I would not build a conventional house if a client asked me to.”

Just a few years ago, it was impossible to achieve a five-star rating in Austin; simply, it was only a three-star program. “We evolved it into a five-star system as more options became available and [environmental] standards got higher,” says Mary McLeod, coordinator for the residential segment of the Austin Green Building program.

That speaks volumes for how far green building has come in terms of availability. Once the bugaboo of sustainable building, sourcing products at a competitive price is now much less of a barrier.

Holt's per-square-foot costs range from $110 to $220, and the 5 to 10 percent cost premium he typically incurs (and passes along) to build green is due to a learning curve in design and labor, not products. “I used a lot of standard products that were inherently green, so they were not more expensive,” he says, also noting that he received standard-length price guarantees and delivery lead times, as well. Holt also got price breaks on his direct purchases over the Internet, while suffering only minor premiums for the no-VOC paints and glues he used. “Availability has improved considerably over the last five years.”

That is, if you know what you need. The only barrier presented by suppliers, Holt says, is one of education. “Most conventional lumberyards and supply houses are not very informed [about green building], requiring builders or homeowners to really educate themselves and specify what they want,” he says. “To change that, a dealer is either going to have to be self-motivated or have an educated customer base driving the evolution.”—Rich Binsacca is a contributing editor for PROSALES.