I developed the EcoSmart stud (ESS) during a 2017-18 new home build I designed for Continuous Insulation (CI). I ended up shelving the CI part of the build due to cost. Just the cost of the exterior ridged foam boards and labor to install it in 2017 was $6,500, and that didn’t include a lot of extra costs that I found out about but didn’t feel like counting at the time. The CI update was not nearly as inexpensive as I had thought.

I decided to go with what is called Flash and Batt insulation, 1,5 inches of spray foam gives a boost to the insulation value, seals the chamber and is the vapor barrier. Then fiberglass batts are added to fill in the rest of the chamber. The upgrade cost for an R-60 attic, 1.5” spray foam, back filled with fiberglass batts, and a couple wall sections of full spray foam was $3,000.

It was far less expensive than the CI insulation but not as a significant gain in overall insulation value due to heat loss through the studs. The whole point of CI insulation is to bring up the insulation value of the framing (most of the framing is the wall studs).

For us here in cold climates, CI insulation is like putting on a second coat. The first old coat doesn’t work really well, so I’m cold. Solution: put on a second, more expensive coat. The two coats work OK together, and I’m overall warmer. I just might not be able to get up if I fall in the snow (think A Christmas Story).

The EcoSmart Stud solves the cost problem (and wearing two coats). If the 2×6 ESS studs were available in 2017, it would have added $1,280 to my $3,000 insulation upgrade for a total of $4280. I would have had an equivalent insulation value of the CI insulation that I had designed the house for at $2,220 less! And that is based on where I stopped counting!

• 2017 CI Package upgrade cost of labor and foam: $6,500
• ESS package $1,280 ESS + $3,000 insulation upgrade: $4,280
• Difference: –$2,220

Hands down, it’s a better wall system to boot. The close cell spray foam in the chamber seals the wall against air infiltration, structurally reinforces the wall, and is the vapor barrier. Plus, it simultaneously insulates the chamber and framing. (it’s a far better coat).

Plus, now I can walk in the cold and snow with confidence! With my new coat, no worries about falling down and not being found till spring!

P.S. It works the same way for warm climates!