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Potentialandlimitationsofusinghardwoodlumberasrawmaterial
forCLT.
HenryQuesada,BrianBond,Sailesh Adhikari
2018WestLafayette,IN
Agenda
• Marketsforwoodproducts• CLTproductionprocess• ResearchonhardwoodCLT• ChallengesanddriversforhardwoodsCLT• Finalthoughts
Logs
Mills
PaperMills
Bioenergy
Softwood
Hardwood
Veneer
EngineeredPanels
-Structuralpanels-Non-structuralpanels
Non-structuralpanels:decorativeplywood,MDF,HDF,particleboard,hardboard
-Strength-gradedlumber-Industriallumber-Engineeredwood-Animalbedding
-Industriallumber-Appearance-gradedlumber-Engineeredwood--Animalbedding
Decorativepanels
Paperproducts
Firewood,pellets,briquettes,advancedliquidfuels
Barkandwoodchips
Blackliquor,bark
Bark,sawdust
Bark,sawdust,blackliquor
Roundwoodprocessing
-Utilitypoles,logcabins,fencing
Sawdust,bark,andwoodchipsStructuralpanels:plywoodandOSB
Industriallumber:pallets,cranes,railroadties,cranemats,miningproducts,rails
Appearancelumber:furniture,kitchencabinets,millwork,musicalinstruments,crafts.
Engineeredwood:LVL,PLV,SVL,CLT,Glue-lams
Strengthlumber:residentialandcommercialconstruction,pallets,decking,fences
Foodindustry:wineandwhiskeybarrels,foodadditives
*ByHenryQuesada®2018
Marketsforwoodproducts
Sawdust:Bionenergy andEngineeredpanels
Bark:Mulch,filling
Woodchips:Papermill,EngineeredPanels,Bioenergy
Stavemills
Engineeredmills
Bark,sawdust,woodchips
Marketsforwoodproducts
• Impactsonenergyandglobalwarmingpotentialis16%and31%lesswhenusingtimberinsteadofconcrete.
• Energyandglobalwarmingpotentialis17%and26%lesswhenusingtimberthansteel.
http://www.themostnaturalresource.com/green-building/
Cross-laminatedtimber(CLT)
• ANSI/APAPRG320-2012 :Aprefabricatedsolidengineeredwoodpanelmadeofatleastthreeorthogonallybondedlayersofsolid-sawnlumberorstructuralcompositelumber(SCL)thatarelaminatedbygluingoflongitudinalandtransverselayerswithstructuraladhesivestoformasolidrectangular-shaped,straight,andplanetimberintendedforroof,floor,orwallapplications.
CLTProductionProcess
IsMC=12%andgrade>=2?
Yes
No
Rejectlumber
Lumbersupply
Cross-cuttingtoeliminate
defects
Fingerjointforlong-boards
Long-boardscutting
Crossandlong-boardsbuffers
Glueapplication
Vacuumstaking
Press(flat/edges)(0.8N/mm2)
CNCroutingPanelsneedrepair?
Manuallyrepair
Yes
Sandingandfinishing
Labelingandpacking Shipping Installation
ExampleofCLTline(Ledinek):-50m3/shift-1100KWrequiredpower,-Upto14mx3.2mx0.4mpanelsize
No
CLTProductionProcess
Processsystem TotalDirectCost Indirect Cost TotalCapital Cost
Manual $9.8 $5.3 $15.2
Automated $11.6 $6.2 $17.9
• Capitalcostfora30,000m3 CLTplant(millionsofUSdollars)*
*EvergreenEngineering.IWF2016.
CLTmarketpotential
• DemandintheUSby2020isestimatedin300,000m3*
– 1m3=424bf• Currentmanufacturingcapacityislessthan34,000m3
– Currentproducers• DRJohnson(4,555m3)andSmartLam (29,000m3)
– Newplantsannounced:• International Beans:Dothan,AL.Announced inJan.2017
– 227kft2 facility.$20million investment– RawmaterialisSYP
• Katerra: Spokane,WA– 250kft2
• EuropeanCLTproducersaverage50,000m3 peryear
*EvergreenEngineering.IWF2016.
CLTstandardsintheUS• PRG-320revision,lastmodifiedin2017*
– Acceptanysoftwood recognizedbyALSC• MosthardwoodhavedesignvaluesinNDS
– SpecieswithSG>=0.35• MosthardwoodshaveSG>=35• Selectedhardwoodshavehighermechanicalpropertiesthansoftwoods
– Grades#2&betterforparalleland#3&betterforperpendicularlayers• YP2COMandlowercouldmakeup#2&betterin
– MC,12+-3%• Mosthardwoodsdriedtolowmoisturecontent(~8%)
– Dimensions• Thicknessoflayers:5/8”<thickness<2”• Parallellayersw>=1.75xthickness(strongaxis):Exclude2x2,2x3dimensionsizes• Perpendicularlayersw>=3.5xthickness(weakaxis):Exclude1x2,1x3,2x2,and2x4dimensionsizes
– Hardwoodsarecommonlysawnto4/4”thickness– Hardwoodlumberissoldinrandomwidths
– Adhesion• Highercapacitypressisneededforhardwood(strongerandstiffer)• HigherdensitycouldcausemorestressesintheboldlineduetohigherdimensionalchangesfromMCvariations• Extractivesinhardwoodcouldinterferewithgluing(aciditymaychange)
– Revisedevery5years• QuesadaisavotingmemberofthePRG-320technicalCommittee• Needtoproducemorehardwooddata
– Stiffness,bending,acoustic,fire,delamination,etc.
*Espinoza,O.andBuehlman,U.2018.CLTintheUSA:OpportunityforHardwoods?CurrentlyForestryRegions.January.
• YellowPoplarCLTmechanicalproperties*– 6/4#2CommonYellowpoplar– 3plypanels,usePFasglue
• Bendingstiffness andstrengthandresistance todelaminationexceededrequiredvalues inPRG-320
• Stronganddurableadhesivebonds
ResearchonhardwoodCLTatVT
MechanicalProperty,YellowPoplarCLTs
% DifferenceWithSouthernPineCLTs
%DifferencewithGradeV1CLTs
BendingStrength,FbS 20.4% 61.9%
BendingStiffness,EI 41.3% 29.4%
*Hindman,H.,Bond,B.,Loferski,J.,Quesada,H.2012-2015.DevelopmentofLow-GradeHardwoodCross-LaminatedTimbers.USDA-NIFA.$300k.
ResearchonhardwoodCLTatVT
• Costconsiderations– LumberpricesforYPandSYP(asOct.2017)• Productionmixasanalternative
NHLA prices ($/bf)Lumber grades
FAS 4/4 1COM 4/4
2COM 4/4
1x6 Pallet
1x8 Pallet
FAS 6/4
1COM 6/4
(2COM 6/4
Pallet 6/4 x 6
Pallet 6/4 x 8
Price 1.03 0.66 0.48 0.34 0.34 1.05 0.78 0.54 0.34 0.34SPIB prices ($/bf)
Lumber grades
#1 #2 #3
Price 0.45 0.42 0.30
ResearchonhardwoodCLTatVT• Quesada, H.,andBond,B.$209K.
USDA/Wood Innovationgrants.Development ofhardwoodcross-laminatedtimber.– Simulation ofmixed-production
• Foralllogsasawingpatterwasasfollows:theouterboardsforeachlogwerecutto4/4”thicknessandtheinnerboardswerecutto6/4”thickness.
$45.08
$57.88$67.50
$44.98
$58.33$65.52
$48.71$55.68
$0.00$10.00$20.00$30.00$40.00$50.00$60.00$70.00$80.00
Dia12 Dia13 Dia14
Revenu
e
Logdescription
RevenueComparisionNHLA NHLA+SPIB Control
Log group
N Dia (in)
Grading
Red 9 12 NHLA+SPIB and NHLAPink 7 13 NHLA+SPIB, and NHLAWhite 5 14 NHLA+SPIB, and NHLAOrange 10 12 NHLABlue 8 13 NHLATotal 39
ResearchonhardwoodCLTatVT
• Whatwerethebarriersthatimpacted theinitialproductionandcommercialization ofCLTsystems inWesternEuropean companies?
• Whatarethemoresignificantdrivers andchallenges forthecommercialization ofCLTsystems?
• Methods:– interviews andtoursoftopthreeCLTproducers inWestern Europe– Interviews ofCLTsuppliersatthe2017Ligna tradeshow inGermany.Demographicaspect Company1 Company2 Company3
CLTproductioncapacity 65-75thousandm3/year 65-80thousandm3/year 95 thousand m3/year
Species SpruceandFir Spruce Spruce
Markets Europe,AustraliaandtheUSA
Global Austria,Germany,France,UK,Italy,Sweden,NorwayandtheUSA
Numberofemployees 50 40 175
TimeproducingCLTsystems
Since2008 Since2012 Since1999
ProducedproductsbeforeCLT
Lumberandengineeredwoodproducts
Lumberandglulams None.Firstproduct
*SoftwoodExportCouncil (SEC)grant
ChallengestostartoutCLTproduction
Productionsetup
LackofCLTmarkets
RawMaterials supply
Vertical integration
CLTcodeacceptance
CLTknowledge
Success
Profits
Manufacturers’perspective:
Financial•Revenue•Profits•Return of investment
Driverstostart-upCLTproduction
Collaborations•Industry andUniversity•Innovation
Productuniqueness•Customization•New product•Renewable material
Infrastructure•Transportation network•Currentmanufacturing
Verticality•Sawmill•Glulam•CLT production
Integration•Architects•Engineers•CLT production
Rawmaterial•Quality•Consistency•Closeness
Technical support•Education•Technical specifications•Post-sale
Pioneering•Innovation•First in the market
CommercializationBarriersofCLTs
Buildingregulations
Fireproofacceptance
Shippingandlogistics
Currentproductioncapacity
CLTadvantagesnotknown
Comm.from/toarchitects
NeedpolicyforCLT
Successfulcommercialization!
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-Outsideeurope-Containershippingislimited
-Norelevantmfg capacityintheUSA-Europeancapacityisbookedfor8months
-FireproofengineersinEuropestillquestionCLT
-UseofCLTinpublicbuildings-Designto
manufacturingflowofinformationneedstobeimproved
-Engineers-Architects-Generalpublic-Government
-Buildingcodes
Finalthoughts
• BarriersandchallengesimpactingthesuccessofCLTmanufacturingandcommercialization
Markets
Manufacturingtechnology
Logisticsoperations
PerformanceofCLTsystems
Informationflow
Educationalactivities
Verticalintegration
Rawmaterialsupply
TheCLTdorm-buildingattheUBCcampus
• Acknowledgements– OmarEspinoza,UM– DanHindman,VT– BobSmith,VT– USDA/WoodInnovationgrants– SothernExportCouncil– USDA/NIFA
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