‘SUMMARY ‘The Pacific Northwest Laboratory (PNL) conducted this study for the Bonneville Power Administration (Bonneville) of the U.S. Department of Energy (DOE). The purpose of this study was to investigate the possible use of structural foam-core building panels in manufactured housing. With the initiation of the Bonneville- sponsored Manufactured-Housing Acquisition Program (MAP) on April 1, 1992, the energy efficiency requirements for Pacific Northwest manufactured homes have increased dramatically. One focus of MAP is the amount of glazing area per home. Previous regional eneray-efficiency programs, such as Super Good Cents.(SGC), limited glazing area because higher amounts of glazing can compromise a building’s thermal performance. MAP allows unlimited glazing but requires the use of expensive vinylframed, argon-gas-filed, low-emissivity-coated windows. Structural foam-core panels (foam panels) consist of a rigid insulating foam core sandwiched between two structural facings. They provide superior thermal performance that might allow the use of less-expensive windows, larger window area, or less insulation in energy-efficient manufactured housing. This study initially reviews foam panel materials, fabrication processes, and construction techniques and details. Types of foam include expanded polystyrene (EPS), extruded polystyrene (XEPS), urethane, and polyisocyanurate. Typical structural facings used are either panelized wood or steel. Panel fabrication is either conducted with an adhesive applied to a pre-cut foam core then cold pressed between the facings, or the foam is poured into pre-spaced facings and the foam cures to bond to the facings. Foam panel construction techniques are distinctive and are included in this report. Foam panel cost would be a significant factor for the manufactured housing industry because the industry is cost conscious. Foam panel cost is a function of the foam type, foam thickness, facing materials, volume ordered, and the foam panel plant production capacity and utilization. Table S.1 presents estimated costs, based on real-world data, for a fully finished standardized wall (40 foot wide by 8 foot high) of various construction types. The materials and labor costs for foam panel construction are comparable to costs for "stick-built" construction. However, the capital and indirect costs resulting from inventory and partial capacity utilization make foam panels more expensive.