Patrick T. Johnson, P.E.

My current engagement is a full time engineering position with Kingspan Insulated Panels, Inc., a global leader in foam core insulated metal panels as well as foam insulation itself. I am a professional engineer in good standing, holding licensure in (5) states, namely Ohio, Pennsylvania, New York, Massachusetts, and Connecticut.

My normal duties at Kingspan include:

• General technical services.
• Research & development of new products and applications.
• Assurance of building code compliance.
• Product testing for structural performance ASTM E72 & FM4881, thermal resistance ASTM C1363 & C518, air & water infiltration ASTM E283 & E331 + AAMA 501.1, and fire classification NFPA 285 & 286 + ASTM E84 + FM4880, seismic performance AAMA 501.4.
• Project specific calculations for structural performance, wind/snow load resistance.
• Thermal modeling calculations of panel joints and wall/roof assemblies.
• Integration of products with associated materials such as windows, curtainwall, mechanical louvers, translucent panels.
• Providing technical support for sales team, designers, architects, and project engineers.
• Training of new hire engineers.
• Product installation training.
• Trouble-shooting, resolving field application issues.

I hold one (1) U.S. patent US2018/0291635 A1 'Building Panel' obtained in 2018. I have developed and am the gatekeeper of the North American structural calculation software for Kingspan that is unique to metal-faced foam insulated panels. I am currently involved in the creation and release of a global software calculation tool for structural evaluation of all Kingspan metal-faced insulated panels, acting as the primary U.S. technical contact.

My private engineering company, Newline Engineering was registered with the Ohio Secretary of State on August 14, 1995. I operate as sole proprietor. Work done is performed independently of my full time employment with Kingspan Insulated Panels, Inc.

My expertise in this endeavor includes:

• Preparation of construction drawings for application of various insulated and non-insulated metal panel systems for commercial construction projects.
• Preparation of stamped structural calculations for light structures and various metal panel products.
• Design of residential dwellings, garages, out buildings.
• Inspection of structures, trouble-shooting of problems, recommendation of solutions.
• Construction and fabrication drawings for Structural Insulated Panels (SIPs) used primarily for residential construction. This type of panel comprises an expanded polystyrene foam core of 6" to 10" thickness with oriented strand board (OSB) facings bonded into a rigid sandwich construction using structural adhesives.

In 2010, I prepared all structural load-span charts for Lamit Industries, Inc., a SIPA (Structural Insulated Panel Association) listed manufacturer of SIPs. In 2020, I worked with ICC Evaluation Service, providing span charts and calculations to include three (3) additional foam core insulated roof deck panel products (Tectum IIIW, Tectum IIIE, and Tectum V) into the finalization of ICC ESR-1112 evaluation report. These products are manufactured by Tectum, Inc., Newark, Ohio.

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During this time period the "Benchmark" operation was owned by Metecno Group, the "parent company" which is headquartered in Milan, Italy. Metecno owned several other foam insulated panel manufacturers in the U.S. located in Modesto, CA, and Deland, FL, as well as Morin Corporation, a single skin metal siding manufacturer in Bristol CT and Fontana, CA. I was involved in the design and installation of a 2 million dollar discontinuous foam line, built in Italy and installed at the Columbus Ohio plant. This line blended bulk polyol and isocyanate chemicals with a gaseous cyclo-pentane blowing agent to form polyisocyanurate core metal-faced panels. This became our very first foamed-in-place product.

My normal duties during this engagement included:

• Research & Development of foam insulated panel products.
• Testing a certification necessary for code compliance.
• Development of product guide specifications.
• Development of structural load-span tables.
• Installation training.
• Technical assistance at trade shows along with building of display booths out of product.
• Training of newly hired engineers.
• Trouble shooting, resolution for issues in the field.
• Technical assistance for sales team, architects, project engineers.

I was an active member of the Metal Construction Association (MCA) Foam Panel Council during this time period, assisting with creation of publication "Technical Performance of Metal-Faced Foam Insulated Panels". I also authored two technical articles in trade magazines:

• "Sophisticated Laminating Process Behind Production of Flat-Faced Insulated Panels" Metal Architecture, January 2000
• "Successful Integration of Metal-Faced Foam Core Panels with Standard Thru-Tube Curtainwall Systems", Metal Construction News, November 2006

My employment at Metecno-Benchmark was transfered to Kingspan Insulated Panels in 2008 when all U.S. Metecno Group companies were sold to Kingspan Insulated Panels, Inc. through direct acquisition.

During this time period I relocated from Pennsylvania to Columbus, Ohio to assist with the start up operation of equipment that was purchased and relocated from former panel manufacturing operation in Farrell, Pennsylvania.

Under new ownership (a division of Lamit Industries) my normal functions included:

• Setup of manufacturing line at the new location.
• Training of production workers.
• New marketing literature launch.
• Product testing and calculations.
• Estimating and shop drawings for projects.
• Qualification and setup of new vendors.
• Research and development of new adhesive with new method af application.
• Participation in first trade show by the Metal Construction Association (MCA).

Benchmark had always been a manufacturer that produced foam insulated metal panels using a laminated method of construction in which profiled metal facings where bonded to pre-cured polyisocyanurate foam core board stock using structural adhesives. Panels were placed under compression using large platten presses.

Fierce competition continued during this time period by large scale competitors that mass-produced similar panels using a foamed-in-place process. The foamed-in-place process is a continuous line methodology whereby polyisocyanurate foam (a blend of polyol and isocyanate) is created in the presence of a gaseous refrigerant, injected in liquid form between the metal facings. Extensive study of this process was necessary in order to convince architects and designers that our laminated method of production was equal to or better than the foamed-in-place industry norm. I wrote countless technical letter during this period which outlined performance comparisons of the these two different production methodologies.

Thermal performance testing at that time was done by a "Guarded Hot Box" test per ASTM C236 that comprised a nominal 6 ft x 6 ft foam panel assembly wall that separated a hot room from a cold room. Heat transfer through the foam panel test wall was measured by watts of heat that must be added to the hot side room to maintain a steady rate of transfer. I build the test wall product specimens for this testing, witnessed the procedure, and the results. Other tests performed includes structural testing, air & water infiltration, bond strength, humid aging, and cyclic fatigue testing.

Benchmark Industries, Inc. was my first permanent employment after securing my B.S. engineering degree from Penn State. This was the start up insulated metal panel company which evolved over nearly 4 decades to become a very successful division of Kingspan Insulated Panels, Inc. where I am currently employed full time.

I entered Benchmark as first employee working along side with president CEO, and vice president. The initial insulated metal panel featured a unique Phenolic foam core manufactured by Koppers Company in Bridgeville, PA. The phenolic foam core had extremely low flammability characteristics and maintained a thermal value of R-8 per inch thickness without thermal loss over time. This exceeded industry standards at the time, and even attained approval for use in New York City (a jurisdiction that forbid the use of foam plastic outright).

I developed and tested the product extensively on a very limited start up budget. Vendors were set up, and production equipment was implemented in our manufacturing facility in Farrell, Pennsylvania. We maintained a hired workforce of approximately 40 very dedicated individuals, many of whom were seeking new employment due to the shut down of Sharon Steel in adjacent Sharon, PA.

During this endeavor, I learned the basics of foam insulated panel design from a pioneers in the industry John A. Hartsock (author of "Behavior of Foam-Filled Structures") and William Jamieson II, P.E. of Hudson, Ohio. I developed standard details for construction using the product, estimated and/or and prepared shop drawings for approximately 200 projects. This was a very exciting period of time with new product launch amongst fierce competition by three other well established manufacturers of similar product.

We vigilantly fought an uphill battle for acceptance for 6 years, after which time the company was forced into closure due to extreme financial difficulty that proved insurmountable.

During college breaks (summers) of 1981, 1982 and 1983, I worked as a draftsman at Plasteel Products Corp. where I generated shop drawings for exterior metal siding on power generating facilities and other buildings.

• Interpreted technical drawings, schematics and computer-generated reports to make revisions to CAD drawings.