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Construction Technology for the 21st Century
LeepCoreTM Structural Insulated Panel (SIP)
Galvanized Steel Clad R25 Insulating Core
LeepCoreTM Structural Insulated Panel (SIP)
and Integrated Building System
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Table of Contents
• LeepCore Markets
• LeepCore Buildings
• Tests/Certifications
• Contacting LEEP
• The Product
• The Technology
• Manufacturing
• Applications
Construction Technology for the 21st Century
The LeepCore Solution:
• Is based on tested and proven product and
technology
• Supports hurricane-force building designs
• Effects major energy cost savings
• Ensures substantial reduction in construction time
and cost
• Provides long lifespan and low cost maintenance
• Features high-speed mass production
• Is resistant to mold, termite, fire and water damage
• Lowers insurance costs
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LEEP Inc. is the creator and manufacturer of the patented LeepCore™ structural insulated panel (SIP), the revolutionary building material designed for the 21st Century.
LeepCore is a galvanized steel skin, polyurethane foam core, load-bearing SIP that is used to construct walls, roofs and floors. LeepCore enables buildings to be built stronger, lighter, and more quickly than with traditional building materials.
The LeepCore Product
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Product – Green Building
Conserves Energy: The LeepCore SIP is among the most energy efficient construction components available, with integral R25 insulation, plus a full thermal break. A LeepCore building saves 40% or more on heating/cooling costs and the associated precious energy and scarce fossil fuels.
Preserves the Environment: Reduced fuel consumption means fewer greenhouse gases. LeepCore uses no increasingly scarce lumber from shrinking forests. LeepCore contains no CFCs or formaldehyde, which could harm the atmosphere of your home or office and the planet. LeepCore also releases no compounds or allergens associated with “sick” buildings.
Builder and Owner Savings: LeepCore buildings can be eligible for a broad variety of energy conservation savings, including incentives, rebates, tax credits and deductions, from DOE Energy Star and LEED programs, to state and regional programs such as CA Green Building Initiative and NESEA, to European carbon credits, and additional incentives likely coming soon to the U.S. in the upcoming energy bill, to name just a few.
No other construction material exceeds our product in providing a combination of energy conservation, environmental preservation, and enhanced protection from unpredictable, destructive and worsening weather.
Product – Affordability
LeepCore buildings are price competitive with traditional building methods,
and erect much faster, substantially reducing construction costs. The
LeepCore components of a building can remain essentially maintenance free
for decades, saving dramatically on upkeep over time. In addition, the
reduced energy for heating/cooling means lower upfront costs on equipment,
and increasingly important, continued long-term savings on energy.
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Product – Key Features
Environmentally friendly
Quick, low-cost assembly
Best industry strength-to-weight ratio
Wind resistant to category 5 hurricane
Certified R-25 insulating value
Mold, mildew, and rot proof
Termite, insect, and pest proof
Near zero maintenance
Virtually soundproof
Waterproof and fire resistant
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Integrated Building System
The LeepCore panel is designed to form panel sections, which in turn form
walls, roofs and floors. This component/modular approach optionally
integrates the LeepCore panel into all facets of a completed building, using
the LeepCore Integrated Building System.
Walls easily bolt to floors Panel section assembly Framed window opening
LeepCore panels are factory cut to the millimeter
up to 12’ long. Panels or assembled sections can
be factory ordered. Complete kits can be ordered
with all necessary precut panels and assembled
sections to fulfill architectural plans.
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A technological breakthrough A first: proprietary roll-formed metal geometries, proven chemistry and high-speed manufacturing machines are brought together to produce a stress-skin component with which to construct walls, roofs and floors. To our knowledge, no other material in the world (composite or monolithic) can boast that it has the certified strength and inherent attributes that are required to serve as commercial code, structural: wall, roof and floor. Patented LeepCore high performance structural panels are formed from class 1 polyurethane insulating foam sandwiched between structurally-shaped steel sheets. Each panel can withstand compression, tensile and shear forces hundreds of times its own weight. Optionally requiring no wood, steel or concrete frames, LeepCore buildings are a virtual thermos, maintaining indoor climates while keeping the elements and noise out.
LeepCore Technology
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Principle of strength in geometric design
The “I-Beam” Effect
Uncombined Combined
3 pieces of material Same 3 pieces configured with little strength to provide great strength
Technology - Strength
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Specialized equipment
LEEP developed an advanced-design metal roll-forming
machine to create “intricate geometric” shapes at speeds
up to 100 feet (30.5 meters) per minute. These shapes are
formed in steel sheets, which become the top & bottom
skins for LeepCore (pre-cut, or continuous process ).
Bottom Skin
Top Skin
Technology - Steel
• Highly insulating core
• Strong polyurethane interface/bonds between
coated metal skins and foam cores.
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Chemical bonding of metal and foam
Combining “Iso” and “Polyol” chemicals in LEEP’s
process triggers an instant exothermic chemical reaction
that produces more than 200 degrees Fahrenheit of
internal temperature that catalyzes the formation of:
Technology – Foam Core
A product’s reliability is best judged by its longevity and the level of technical refinements of the method used to manufacture the product. Stress-skin metal/foam lamination technology has been used and refined for non-structural construction since the early 1960’s. LEEP has further improved this technology with proprietary and patented techniques, and leveraged that to design and build a revolutionary metal-clad SIP building material.
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.019” (0.5 mm) Metal skin with deep pattern embossed polyester coated surface.
LEEP combines “I-Beam” geometry with a stress-skin manufacturing process to produce the LeepCore Structural Insulated Panel (Steel SIP).
Three strategically placed reinforcement strips for superior strength at attachments.
Deep (2½” x 4”) integrally roll-formed channel. Hidden roof and foundation connections, and alternately wiring chases and point-load support members.
Technology - Combined
Combining the principles
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LeepCore provides multi-directional high-force resistance that resists floor and
roof (transverse) and wall (axial and in-plane) forces to levels in excess of
commercial building-code requirements. LeepCore can become the entire
building enclosure for a wide array of different types of buildings.
Technology – Shear Strength
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Relative material weights (lbs/cu. ft.)
At 9 pounds per cubic foot (3 pounds per square foot), LEEP can ship
multiple buildings: per carrier, at the same time by: flat-bed truck,
container, air cargo, airdrop, rail, or sea.
LeepCore
Wood
Concrete
Metal 9
10-50
150
300
Weight Comparison
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Comparing relative number of parts & labor Traditional construction vs. LeepCore construction
Framing 4’ x 8’ Sheathing Insulation 4’ x 8’ Wallboard
6 - 2 x 4s
+ 16 Framing Nails
1 Sheathing Panel
+ 72 Nails
3 Insulation Batts
+ 66 Staples
1 Sheet of Wallboard
+ 54 Nails
=219 Components for insulated wall + brick or block count (if applicable) + hours of labor
LeepCore offers up to 8’ X 12’ wall, roof and floor Sections
= 13 Components for one LeepCore panel section delivered from factory + 4 nuts/bolts/washers + Minutes of Labor
Construction Methods
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Attributes
LeepCore
Wood Frame
Wood/Foam Panels
Metal
Concrete Block
Concrete Tilt-up
Self Supporting High High High High High High
Energy Efficiency High Medium High Low Low Low
Strength/Weight Ratio High Medium Medium High Low Low
Fast Erection (Fewer Parts) High Low High Low Low Low
Water/Rot/Mold Resistance High Low Medium Low Low Low
Termite Resistance High Low Low High High High
Fast Erection (Labor Savings) High Low High Low Low Low
Wind Resistance High Low Medium High High High
Seismic Force Resistance High Low High Low Low Low
Life-cycle Savings on Maintenance
High Low Low High High High
Competitive Installed Cost (Regional Variations)
Medium Medium Medium Medium Medium Medium
Value Comparison
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Coated steel coil inventory
Manufacturing Elements
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Manufacturing Elements
Steel skin cut-to-length line
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Manufacturing Elements
Roll forming – bottom skin
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Manufacturing Elements
Roll forming - top skin
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Manufacturing Elements
Panel press manufacturing
Produces up to 12’ (3.6 meter) components
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High-speed LeepCore manufacturing machinery
will produce 80 square feet per minute
Continuous lamination manufacturing
Manufacturing Elements
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LeepCore Applications
Single Family: LeepCore can be used for almost any style of construction, from affordable to luxury, shipping from the factory with an attractive and low maintenance finish, or supporting the application of most any other traditional exterior finish. Multifamily: LeepCore is ideal for low-rise and mid-rise buildings, able to serve as wall, floor and roof systems. The built-in wiring trenches facilitate complex wiring of multi-unit buildings. LeepCore shortens construction cycles, where time money. Education: LeepCore is suited to both permanent and portable classroom and academic construction. Our product exceeds municipal energy efficiency guidelines, remains mold, mildew and rot free, and creates a comfortable and quiet setting for learning. Commercial: Extensively customizable, LeepCore panels may be used to serve a wide range of commercial uses from retail, to industrial or office. Corporations with many projects, such as chain stores, can leverage the value of factory designed and precut sections that quickly assemble on site. Military and Remote Sites: Lightweight and easy to construct, LeepCore prefabricated structures are ideal for forward deployed military units or any difficult to reach location, such as burgeoning oil sands towns, NGO sites, mining, and others. Emergency and Portable Housing: FEMA, U.S. States, NGOs and others can warehouse and rapidly deploy LeepCore based emergency housing. LEEP builds transportable, easily erected, affordable, safe, reusable, and comfortable designs for government and relief organizations. Other: Yes
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LeepCore Markets
Construction is the third largest industry in the world (behind only energy and food).
LEEP is pursuing commercial projects ranging from office buildings, to hotels, retail stores, and temperature-controlled storage, to name a few. Government opportunities are abundant and varied, including military, FEMA, HUD, Department of State, US individual state programs, and others. US Residential housing starts of 1 million new homes per year represents an available market of over 2.5 billion square feet of just exterior walls. Emerging markets have a tremendous need for affordable, energy efficient, safe housing. Areas of special advantage to LeepCore:
• US Gulf Coast, Florida, Caribbean (Wind/Weather/Heat) • Northern (Cold) - Above 60th Parallel (Extreme Cold) • Middle East (Heat) • South Pacific (Moisture & Termites) • US West Coast/Pacific/Turkey/India (Earthquake) • US Government (General Prospects) • Portable and Emergency Housing (Global)
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LeepCore Panelized Building panel sections
LeepCore Buildings
LeepCore panel components
Typical wall, roof or floor sections shipped from factory are 6’ x 12’ (1.8 x 3.6 meters)
(Panel sections arrive at job site in sizes up to 10’ x 12’)
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Two story office building
Houston, Texas
LeepCore Office Building
Surpassed stringent Port of Houston high wind building code. Came through hurricane Ike unscathed.
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Second story Floor Support System
Intermediate floor support system: Spans 6’ X 18’ openings. Note: wall-
embedded, hidden point-load supports.
Construction Detail
LeepCore Portable/Emergency
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Modular building, ships under international 20’ x 8’ x 8’
container code. Easy assembly. Reusable.
Available in various sizes and configurations, including custom. Model shown is 480 square feet (20’ x 24’). Units are stackable.
LeepCore Special Purpose Buildings
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• Mail Screening Facilities
• Wind Turbine Utility
• Railroad Crossing Control
• Safety/Emergency Shelter
• Other
Each unit provides a fully
self-contained, conditioned,
sealed environment.
• Lightweight, but stronger than steel competition
• Fully sealed (no contaminant leakage)
• Sanitize-able (inside and out)
• Heat welded floors
• Transportable, including ISO lift holes and forklift pockets.
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Simulated split-face block (Polymer based)
Stucco Flex simulated- stucco polymer, with integral
6’’ decorative detail Conventional gypsum
wallboard
LeepCore Building Finishes
LeepCore is architecturally transparent; i.e., the finished buildings can look however an
architect chooses, or the factory finish (deep-pattern embossed) can become the final
exterior, and in some cases, the interior surface. Building finishes available: paint, gypsum,
wood, synthetic or polymer stucco, full/split brick or block, stone, tile, granite or marble.
Examples:
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LeepCore School Project
Five-building classroom campus for 500 children in Baker
County, Florida. LeepCore serves as: all perimeter bearing
walls, the structural roof system, and selected interior walls.
Baker County Florida educational campus A new generation of classroom buildings
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Baker County Florida Campus
38 classrooms, 5 new buildings
A rapid growth in students and the mandate for voluntary Pre-K…..
Baker County needed 5 buildings and 38 classrooms in 10 months.
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Baker County Florida Campus
Less than 3 weeks…A completely erected, dried-in, 88’X120’, 8 classroom building
LeepCore panels represent the
complete building enclosure as
structural walls and roof.
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Baker County Florida Campus
A quality solution for permanent classrooms from contract to occupancy in less than 8 months
Fast Delivery. Cost Effective.
LeepCore supports quick, lower cost, turn-key building construction
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Baker County Florida Campus
POLO LACAYO President, Ironwood Construction
“We have been on site for exactly three months. Building #1 and #2 are ready for occupancy...Building #3 will be in two weeks, and the last two are already dried in and ready for trades!
I actually think the word “Awesome” came out of my mouth”
PAULA BARTON Superintendent of Schools, Baker County
“Our desire was to be at the forefront
of timely and efficiently constructing a
state-of-the-art facility. It is a
welcoming campus that has high
aesthetic value. The LeepCore
constructed facility provides an
optimum learning environment for our
children.”
LeepCore supports “high aesthetic value” construction
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THE TEACHERS
“We are elated to be at the new
center. The bright, open,
spacious classrooms are a
blessing. Every visitor
comments on our beautiful
school.”
SHARRIE RAULERSON, Principal
“We are very pleased with the buildings. Thank you
for making this a great experience for us. We look
forward to being a model for others to see what a
fabulous school we have. The new center is
providing a quality school experience for our
students.”
Baker County Florida Campus
LeepCore ensures end-user satisfaction
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LeepCore affordable homes can be completed swiftly. Proper scheduling of erection crews will ensure rapid completions of weather structures. Window/door crews, scheduled tightly in behind the enclosure erection crews, allows completion of each 1260’ sq. ft. building structure in a few days or less per 5-man erection crew. Partitions, electrical, cabinetry, plumbing, wallboard, fixtures and finishing can then be tightly scheduled so as to complete houses to turnkey levels within 2 to 4 weeks after lock-up of enclosures.
LeepCore Housing
LeepCore supports site-built panelized and modular
construction for high quality affordable housing.
LeepCore Housing
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Uniquely Strong Ceiling/Diaphragm
and Strong Shear-wall Enclosure
Strong (1,500 lbs/linear foot) Shear-force Resistant enclosures ensure
unique wind-tunnel certification of hurricane V (156 MPH) wind rating.
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Tests and Certifications
Hurricane Resistant: Can meet Florida’s 2001 Category 5 hurricane wind zone building codes (156+ MPH). Earthquake Resistant Construction: RADCO certified transverse, axial, and racking shear tests confirm that LeepCore withstands high levels of seismic forces. Strength-to-Weight Ratio: Certified to ASTM E-72 testing procedures for full-wall-distributed-load-bearing and point-load certifications (unsupported panel sections) . Rigid Foam: Foam certified to ASTM D-1621 compressive strength at 20 psi.
Full details of tests and certifications can be found on our web site at
www.leepinc.com/product/tests
P.S.I. Stand-Alone Structural Capacities: Certified to ASTM E-72. Resiliency: Certified to ASTM E-72, LeepCore is resilient, returning to its original shape after load forces abate (recovery of transverse deflection after load removal). Waterproof: Certified to ASTM D-2856, water impermeable. Combustibility: Certified ASTM E-84 (Class 1) fire resistant. Insulation R Factor: Certified to ASTM C-518 @ 7.25 R per inch (0.138K).
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Tests and Certifications (cont)
LeepCore’s peerless core/skin interface bond has never been broken during 10 years of testing and commercial use even in desert summers and frigid winters. LeepCore floor, roof and wall sections hold 100% to 400% greater loads than conventional building materials that are well above LeepCore’s weight category and require wall-frame support systems. LeepCore can serve as the entire building enclosure for many types of buildings LEEP’s metal/foam stress-skin panels bend but do not break under severe load, i.e., failure is not catastrophic. LeepCore panels make the most advanced building system available to support seismic-resistant and wind-resistant building designs.
The structural tests of LeepCore show conclusively that LeepCore provides the necessary structural resistance factors required to build commercial-grade walls, roofs and floors.
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Product – Benefits Summary
Builder Benefits Owner Benefits
• Fast construction:
• Lower insurance cost
• Lower financing cost
• Lower equipment rental cost
• Faster sales cycles/occupancy
• Fewer workers
• More buildings built per season
• Lower HVAC tonnage
• Low maintenance/fewer call-backs
• Marketing advantage
• Fewer materials to manage/handle
• Avoids material shortages
• Green building credits
• Wiring/support/connection trenches
• Energy efficiency (low utility cost)
• Mold, mildew, and rot proof (avoids "sick building syndrome")
• Termite, insect, and pest proof
• Waterproof
• Enhanced safety:
• Wind resistant (class 5 hurricane)
• Wind-borne debris resistant
• Earthquake resistant
• Fire resistant
• Reduced insurance premiums
• Low maintenance
• Long-term durability
• No offgassing
• Sound insulation
• Design flexibility
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Contacting LEEP
www.leepinc.com
Sales: John Nordstrom
502-426-7400
Investor Relations: [email protected]
Corporate: LEEP, Inc.
P.O. Box 24344
Louisville, KY 40224
General Inquiries: [email protected]
502-426-7400
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Built with LeepCore
Construction Technology for the 21st Century
