Sigh... every time I think I have some detail of our house planned, the rug gets pulled out from under me. This time it's the foundation plan, which had been nicely settled since September.
The problem is that we're on a sloping lot, but it doesn't slope steeply enough to have a walk-out basement/garage. So we decided to do a slab on top of a 4-foot frost wall. We were going to follow one of the standard approaches, but Ted lost sleep thinking about where the dew point was going to hit inside of the wall (condensation + studs + tightly-sealed house = mold), so we needed to tweak things.
Marc suggested a material he'd recently heard about called FoamGlas. It's a fairly nifty product: a strong, insulating block with good compressive strength. Just the thing to provide the thermal break in our foundation, which meant the dew point would hit inside the exterior rigid foam insulation where there's no risk of mold. Here's what it was going to look like [click image for larger version]:
Both Marc and our structural engineer approved, so I felt good about the plan.
Ted, however, was a little skeptical, since it's a fairly new product in the US. We called the technical contact at Pittsburgh Corning today to ask some questions, and it turns out that FoamGlas has a cousin in Europe called Perinsul which is designed for our exact purpose and has a much longer track record. Perinsul has higher compressive strength than FoamGlas, and it's also pre-coated with an impervious seal. We could have sealed the FoamGlas ourselves with some asphaltic mastic, but the lower strength and the lack of a history for our application make it a non-starter for Ted.
So now we're back to the drawing board (i.e. Google searches & SketchUp). Pittsburgh Corning is willing to import some Perinsul for us from Belgium, and I asked them for a price quote, but it seems absurd to have foundation blocks shipped overseas (even lightweight ones). The only upside is that it might convince them to start manufacturing these babies in the US.
We asked Marc for some alternatives, and he proposed autoclaved aerated concrete (AAC). AAC is swell stuff (we were familiar with it in Arizona under the name E-Crete), but it's not manufactured in the Northeast. I spoke to a helpful sales rep today who will send me a quote from a factory in Florida, but it's also not an ideal solution.
The General Plastics site was hilarious, BTW. It had an interactive product finder with choices like "Is this an application where you are trying to keep something hot (but under 250 degrees F)?" or "Is this an application where you are trying to keep something cold (+40 degrees F to -40 degrees F)?" And that's just from the section on Thermal Insulation — there are other question trees as well. It's like a "Choose Your Own Adventure" for evil scientists!
Planning this house has been a crazy amount of work for me, but fortunately I can rest once all the specs and plans are finished. Oh, wait, maybe not...
Basement rim joist areas; holes cut for plumbing traps under tubs and showers; cracks between finish flooring and baseboards; utility chases that hide pipes or ducts; plumbing vent pipe penetrations; kitchen soffits above wall cabinets; fireplace surrounds; recessed can light penetrations; poorly weatherstripped attic access hatches; and cracks between partition top plates and drywall.