INTEGRATED STRATEGIES FOR THE WELSH TIMBER INDUSTRY · One of the most significant factors influencing the development of theWelsh timber industry is the relatively low quality of

INTEGRATED STRATEGIES FOR THE WELSH TIMBER INDUSTRYConsidering the potential of an integrated timber technology and economic development strategy

Copyright © Thomas Stoney Bryans 2011

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior per-mission of the copyright owner.

INTEGRATED STRATEGIES FOR THE WELSH TIMBER INDUSTRYConsidering the potential of an integrated timber technology and economic development strategy

THOMAS STONEY BRYANS

This project was undertaken on behalf of bere:architects and BRE Wales. It was made possible through funding from the WEFO/ERDF project “Low Carbon Built Environment”, part of the “Low Carbon Research Institute”, and is hereby gratefully acknowledged.

Cover image © 2010 Google, © 2011 Tele Atlas, © 2011 Getmapping PLC

wales

CONTENTS 0.0 Introduction1.0 STEEPanalysis

2.0 WelshForestry 2.1Areas 2.2SalesandEconomics 2.3TimberQuality 2.4FutureAdaptationandSustainableForestry

3.0 WelshTimberSupplyChain 3.1CurrentSituation 3.2Economics 3.3IntegratedVision 3.4FutureDevelopment

4.0 Welsh+ImportedTimberPriceComparison 4.1TimberPrices 4.2SC3+SC4PriceComparison

5.0 PotentialProducts+ManufacturingSystems 5.1FingerJointing/CladdingSystems 5.2LaminatedTimberBeams 5.3I-Joists 5.4LadderTruss 5.5BoxBeams 5.6CLTPanels 5.7Brettstapel 5.8WoodfibreInsulation 5.9PassivHausWindows

6.0 ExistingWelshTimberStudies

7.0 CaseStudies+Benchmarking 7.1Regional 7.2Businessandtrainingfacilities

References

4

5

8

14

21

22

27

27

28

�

0.0Introduction

Therelativelypoor-qualityofthemajorityofWelshsoftwoodtimber,mostlySitkaspruce,resultsinlargequantitiesbeingusedforlow-gradeproductssuchasfencing,pallets,paperpulp,andbiomass.Thisresearchproposalhypothesisesthatitispossibletoextractgreatervaluefromtheoriginalfelledtimbers,throughthestrategicanalysisandredesignofthesupplychain,andthroughthedevelopmentofnewtimber-technologies,effectivelymovingWelshtimberproductsupthevaluechain.

TheUKgovernmenthascommittedtointroducingnewregulatorystandardsrequiringallnewhomestobezerocarbonby2016;thisstudywillproposethattheWelshtimbersectoriswellplacedtotakeadvantageofthatemergingmarket.Theexistenceoflargesoftwoodplantations,alongwithregionalindustrialexpertise,andtheproposeddevelopmentofaskillsacademyinEbbwVale,couldprovidetheidealconditionsforthedevelopmentofanewindustrythatwouldbesocially,economically,andecologicallysustainable.

TherelativelysmallcoverageofWelshforest,andtheresultantlow-volumeoftimberoutputcomparedtoothermajortimberproducingcountriessuchasFinland,Sweden,andAustria,requirestheWelshtimberindustrytobecomefarmoreinnovativeinaddingvaluetoitsproductacrosstheentiresupplychain.Withanalreadystrongsecondaryprocessingsector,itispossibleforWalestodevelopafullyintegratedsupplyandprocessingchain,enablinglocalproductionfromforesttoend-user.

Previousresearch,suchasthedevelopmentoftheSitkaspruceboxbeamfortheTy UnnosaffordablehousingprojectbyDesignResearchUnitWales(partoftheWelshSchoolofArchitecture),andthemanufactureoftheUK’sfirstPassivHauscertifiedwindowsforbere:architects’Lime House,hasalreadydemonstratedthecapabilityofbothWelshtimberandthemanufacturingindustrytomeettherequirementsfortheconstructionofzero-carbonhousing,withlocallysourcedmaterial.Itisproposedthatthefurtherdevelopmentofthese,andother,low-carbontimberconstructionproducts,withinanintegratedsupplychain,couldenabletheflowoftimberfromforesttoconstructionsite,withzerowood-wastage.

�

1.0STEEPAnalysis

AsameansofunderstandingthebroadercontextoftheWelshtimberindustrytheSTEEPanalysishasbeenusedtoconsidertheSocial,Technical,Economic,Environmental,andPoliticalfactorsthatbothaffectandareaffectedbytheindustry.Suchamodelenablestheconsiderationofawiderangeofissues,fromthesocialbenefitsofwoodlandforrecreationalpurposes,throughtopestanddiseaseresearch,andglobalclimatechangepolicy.BeyondthefiveSTEEPcategoriesasecondarylayerofanalysisisappliedintheformofaHardware,Software,andNetwork(HSN)assessmentofeachsector.TheHSNanalysisbreaksdowntheSTEEPcategoriesintothephysical-Hardware-suchasmachineryandtrees,thetheoretical-Software-suchasresearch,patentsetc.,andthesystemsofimplementation-Networks-suchasjobcreationprogramsthroughtotheinternationaltimbertrade.

ThecombinedSTEEPandHSNanalysesenablefullconsiderationoftheindustrycontext,andbringtolightrelationshipsthatmaynotpreviouslyhavebeenconsidered,suchasthatbetweensocialnetworksandcarboncreditsforinstance,whichcouldresultingreatercommunityinvolvementinwoodlandsthroughthefinancialbenefitsthatstandingwoodlandcouldbringtothelocalpopulations.

HARDWARE

SOFTWARE

NETWORKS

SOCIETY TECHNOLOGY ECONOMY ENVIRONMENT POLITICS

• People• Housing• Community facilities

• Tree felling and transportation infrastructure: chainsaws, trucks etc• Sawmills• Factories

• Studies on the benefits of woodland and forest to people• Social and Demographic data• Employment rates

• Patents• New technologies for manufacturing• Research on new timber construction products

• Social Networks• Community groups• Labour laws• Education• Jobs creation programmes

• Digital communication networks

• Forests as capital reserves• Timber harvesting and processing infrastructure

• Studies on land productivity

• Financial systems• Carbon credits• International timber trade

• Forests• Waterways and water supply• Animals

• Silvicultural systems• Ecosystem and forestry research• Pest and disease research and predicted shift in coverage• Global climate change predictions

• Emissions limitations• Carbon credits• Ecosystem networks

• National infrastructure

• Projected demand for housing

• Building regulations and energy standards• Forestry and woodland policy• Environment and climate change policy

UK AUSTRIA SWEDEN FINLAND

12% 48%

75%

77%

2.0WelshForests

2.1AREAS

ComparedtotherestoftheEuropeanUnion,theUKhasarelativelylowproportionofforestcoverageasapercentageoftotallandarea,withtheaverageforGreatBritainbeingjust11.6%1,placingitfourthlowestcomparedtoitsEuropeanneighbours2,withanEUaverageof37%overall3.ContrastedagainstleadingtimberproducingnationssuchasFinlandat77%coverage,Swedenat75%,andAustriaat48%4,theBritishtimberindustryisatadistinctdisadvantageinshearquantityofsupply.AlthoughWelshforestrycoverageat14%isslightlyhigherthantheUKaverage,itisclearthattheWelshtimberindustrywillneverbeabletocompeteonalike-for-likebasiswithcountriessuchasSweden,insteadrequiringfarhigherlevelsofinnovationandintegrationacrosstheentiresector.

2.1.1KeyStatistics:

2.1.1.1TotalForestandWoodlandCoverage

• Woodlandsoccupyabout14%ofWales(290,000ha)(onlycountingareasofwoodlandof0.1haandover)5

• Scotlandcovers7.8millionhectares,17%ofwhich(1.2millionha)isforested;aspirationaltargetof25%bymid-21stcentury• Englandhas8.4%woodlandcover(1.1millionha)6

• GreatBritainhasanaverageforestcoverageof11.6%7

• The20thCenturysawamajorexpansionofwoodlandsinWales,fromalowpointof5%oflandareaaftertheFirstWorldWar,toalevelof14%today8.Woodlandlandcoverincreasedbyover45000hectaresfrom11.6%to13.8%ofthelandareabetween1980and19979• WoodlandcoverageinGreatBritainincreasedfromanaverageof9.2%to11.6%between1980and199810

2.1.1.2AreabySpecies

• AlmostonethirdofthetotalwoodlandareainWalesconsistsofSitkaspruceplantations11.• ConiferwoodlandisthedominantforesttypeinWalesrepresenting47.9%ofallwoodland.Broadleavedwoodlandrepresents37.3%,andMixedwoodland7.7%12

• ThemainconiferspeciesinWalesisSitkasprucecovering83,891hectaresor56%ofallconiferspecies• Coniferwoodlandismostlysingle-species,single-ageplantations,whicharegenerallymanagedbyclearfelling13

• Themainbroadleavedspeciesisoakcovering42,918hectaresor37%ofallbroadleavedspecies14

• SitkaspruceisthelargestindividualspeciesinWales,accountingforalmost⅓ (31.5%)ofallwoodland.SecondlargestindividualspeciesinWalesisoakwith16.1%.Conifersintotalaccountfor55.9%15

• SitkaspruceintheUKaccountsfor29.1%ofallwoodland,withthesecondlargestindividualspeciesbeingPineat17.2%,withoakaccountingforonly9.4%ofallwoodlandUK-wide16

• PlantingofSitkasprucebeganin1930s,peakingin1960s+1980s17

2.1.1.3PublicandPrivateOwnership

• TheForestryCommissionWales(FCW)controls44%ofWelshforestsandwoodland(127,600ha)18

�

8.4%

13.8%

16.4%

10

• TheScottishExecutive’sForestryDepartmentmanagesalmost40%ofScottishforest(467,000ha)19

• FCWwoodlandisdominantlyconiferous:73.6%(88,287ha),whereasprivateforestsaremajoritybroadleaved:55.7%(83,603ha)20

• VastmajorityofSitkaspruceisinForestryCommissionwoodland:55,322hectares(68%),asopposedto25,993hectares(32%)inprivateorcommercialownership21

• OfFCWSitka,50,137ha(91%)isHighForestCategory122-“Standswhichare,orcouldbecome,capableofproducingwoodofasizeandqualitysuitableforsawlogs”23.Ratioisthesame-91%-inprivateSitkaplantations.

2.2SALESANDECONOMICS

2.2.1KeyStatistics:

2.2.1.1SalesFigures:

Salesvolumes2010-2011:• Englandtotal1.5millionm3

• Scotlandtotal3.2millionm3

• Walestotal770,000m324

• Walesdirectproduction:330,000m3

• Standingsales:440,000m325

Scotlandproduces4timestheamountofWales,roughlyequivalenttotheareaofforest.Englandabouthalftherelativeproducedvolume,consideringitsareaofforestcoverageissimilartothatofScotland.

2.2.1.2EconomyandJobs:

• Around9,000peoplearedirectlyemployedbytheWelshtimberindustry26

• 2009datafromtheONScalculatestheforestsectorinWalestocontribute£429milliontonationaleconomy27

2.3TIMBERQUALITY

OneofthemostsignificantfactorsinfluencingthedevelopmentoftheWelshtimberindustryistherelativelylowqualityofthesoftwoodtimberproduced.Themildanddampclimateresultsinfastgrowthperiods,particularlyforSitkaspruce,whichinturnproducesalow-densityandthereforealowstrength-gradeproduct.

ThevisualgradingofSitkaspruceproducestwostrengthgrades:GS(equivalenttoC14)andSS(equivalenttoC18),withmechanicalgradinggivingreject,C16,andC24grades28.ThemajorityofWelshtimberisofC16quality,withsmallamountsofC24,butintoosmallaquantitytomakeiteconomicallyviablewhencomparedtoforeignimports.WhilstthereisthepotentialforasignificantsupplyofC16gradedtimber,itisnotedbyDennisJonesofWoodknowledge WalesthatthemajorityoftimberprocessedbyWelshsawmillsisneverstrengthgraded,andassuchcannotbeusedtoitsfullpotentialandonlyforlowergradeuses29.

Inadditiontoissuesofstrength,factorssuchasthemaximumavailablesawntimbersizesalsoposechallengesforthedevelopmentoftheindustry.Thisisparticularlyrelevantwhenconsideringtheproductionoftimberframingsystemsforenergyefficientbuildings,withhigherquantitiesofinsulationdemandingagreaterwallthickness.PassivHausstandardsforexampletypicallyrequiresaminimuminsulationthicknessof300mm,whichismosteconomicallyproducedwithinasinglepanel.WithupperlimitsforWelshsawntimberataround215mm,itisclearthatgreaterlevelsofinnovationinengineeredsystemswillberequired.Examplesofthisarediscussedlateron.

CLEARCUTTING IN THE YSTRADFFERNOL FOREST IN THE RHONDDA VALLEYImagecourtesyofForestryCommissionWales

12

2.4FUTUREADAPTATIONANDSUSTAINABLEFORESTRY

CriticaltothedevelopmentoftheforestryandtimberindustryinWalesistheneedtoensureasustainablefutureforthesectorasawhole,incorporatingnotjusteconomicandbusinessconcerns,butalsoenvironmental,ecological,andsocialconsiderationsaswell.

Oneofthemajorchallengeslikelytobeconfrontedbytheindustryistheneedtoadapttoachangingclimate.Althoughtheimpactofclimatechangemaybringsomelimitedbenefitstothesector,suchastheprobabilityoflongergrowingseasonsandtheincreaseinproductionpotentialthatwillresult,thechallengesthatitwillbringwillbesignificant,andneedtobeaddressediftheyarenottofaroutweighanybenefits.Increasesinboththeintensityandfrequencyofextremeweatherevents,suchasstorms,drought,andfirearelikely,asistheemergenceofpestsanddiseasesnotpreviouslyseeninWales,thathavemigratedwiththechangingclimate.AsstatedinThe National Assembly for Wales strategy for Woodlands and Trees,changesinthepatternofoutbreaksforsuchpestsanddiseaseswillposeaparticularlyseriousthreattosinglespecieswoodlands30.

Thecommercialadvantagesofsinglespecieswoodlandsandaclearfellingstrategyisclear:theyproduceeven-agedtreesofthesamespecies,withmaximumtimberyields,andmaximumefficiency.Thedetrimentalecologicalimpacthoweverissignificant,andtakenoveralongerperiodoftimethesearelikelytofaroutweighanyshort-termbenefits.Aswithanymono-cropplantation,therepeatedcultivationofasinglespecieswillgraduallydrainnecessarynutrientsfromthesoil,resultinginlessproductiveplantations.Theclearfellingofforestshasfurtherecologicalimpact,includingissuesofsedimentrunoff,erosion,andwaterquality.Theimplementationofalternativesilviculturaltechniquessuchascontinuouscoverforestry(CCF)shouldthereforebeencouraged.Althoughthisislikelytoresultinlowerrevenuesandhigheradministrativecostsintheimmediatefuture,itwillaidinthedevelopmentandlong-termviabilityoftheindustry.

3.0WelshTimberSupplyChain

3.1CURRENTSITUATION

OneofthekeystrengthsoftheWelshtimberindustryisthebreadthofexpertise,suppliersandmanufacturersthatitencompasses.Fromforests,tobothprimaryandsecondaryprocessing,therangeofproductionacrosstheindustryissignificant,incorporatingeverythingfromsawntimber,low-gradeproductssuchaspallets,fencing,andbiomass,throughtosheetmaterial,andhighvalue-addeditemssuchasfurniture,andcraftproducts1.

Althoughthepotentialfortheintegrationofboththesupplychainandtheindustryingeneralissignificant,thecurrentrealityisonethatislargelydisconnected.AsareportbyJaakko Poyry Consultingstatedin2004“thereisagrowingdisconnectionbetweenthecurrentWelshresourceandprocessing.Around90%ofthehardwoodand65%ofthesoftwoodrawmaterialflowingintotheWelshindustryisimported”2.Asanexample,PremierForestProducts,basedinNewportandoneoftheUK’slargesttimberandpanelwholesalers,sellsnoWelshtimber;theydosupplyaminimalamountofIrishtimber(around5%),whichisclassifiedasdomestic.ThevastmajorityofWelshsawmillshoweverrelyonWelshtimber,withanestimated75%oftheirdemandbeingsuppliedbyWelshforests,andtwo-thirdsoftheiroutputremaininginWales3.AlthoughtheWelshmarketisdominatedbyimports,andisthereforeverycompetitive,thereissignificantpotentialfortheexpansionofdomesticproduction,particularlywhenconsideringthelowerenvironmentalimpactandlowertransportationcoststhatamoreregionalsupplyandproductionchainwouldbenefitfrom.ItisnotablethatininterviewsconductedwithWelshforestryindustrybusinessesfortheJaakkoPoyryreport,that“themarketwasveryrarelymentioned…asabarriertogrowth”4.

OneofthesignificantchallengesfacingtheindustryisagenerallackofconfidenceintheWelshwoodsupplychain5,withtherelativelysmallscalenatureofforestrybusinesses,fromforeststhroughtoprimaryprocessing,beingunabletoguaranteelong-termsupply.

3.2ECONOMICSANDSTATISTICS

AcrossallbusinesseswithintheWelshtimbersector,theindustrycurrentlygeneratesarevenuestreamofover£1.7billionperyear.Thisrisestomorethan£4billionwiththeinclusionoftheconstructionindustry6.Withgovernmentcommitmenttonewregulatorystandardsrequiringallnewhomestobezerocarbonby20167themarketforlow-costandlow-energytimberframingsystemswillexpandconsiderably,andtheWelshtimbersector

1�

iswellplacedtotakeadvantageofthatemergingmarket,andaddconsiderablevaluetotheindustry.

3.2.1KeyStatistics

• ThetotalnumberofbusinessesintheWelshforestindustryisestimatedataround1750.Withinthis,thereisalarge,stronganddynamicsecondaryprocessingbusinessofcloseto1500businesses.8

• Thetotalwoodchainvalue(theannualwoodmarkettransactionsindomesticandimportedwood)is£315millionp.a.ofsoftwoodand£105millionp.a.ofhardwood(includingthewoodequivalentofpulp,paperandrecycledfibreusedinpaperprocessing)9

• Valueaddedandemploymentateachstage10: Forestryandharvesting £26m 1300people Primaryprocessing £167m 1600people Secondaryprocessing £236m 6000people

3.3INTEGRATEDVISION

Aspreviouslystated,therelativelysmallscaleoftheWelshforestryindustry,whencomparedtoleadingEuropeanproducerssuchasFinland,Sweden,andAustria,placesitadistinctdisadvantagewhenconsideredpurelyintermsofsupplyandprimaryprocessing.Itscompetitiveadvantagemustthereforebefoundelsewhere,andrequiresgreaterlevelsofinnovationacrosstheentiresector.Thedevelopmentofahighlyintegratedsupplychain,acrossallaspectsoftheWelshtimberindustry,wouldharnessthemajorstrengthsthatthesectorcurrentlydisplays.Indoingsoitwouldprovideaclearframeworkforinnovation,enablethedevelopmentofhigh-valueproducts,andsignificantlyincreasethevaluethatisaddedalongtheentirechain.Thebenefitsofsuchastrategywereclearlystatedinthe2004JaakkoPoyryreport:

The emerging Welsh forest industry is able to consider, over time, a highly integrated chain from resource to end-user, due to; the current strong secondary wood businesses, the opportunity to establish a high value resource, and the proximity to major markets, in particular the UK. This structure will have neither the single focus on secondary wood businesses, such as Danish furniture, nor the predominance of primary processing such as Nordic countries, Scotland and New Zealand. It will be unique to Wales.11

Throughthecloserintegrationofthetimbersupplychain,itwouldbepossibletodevelopazero-wood-wastagestrategy,enablingtheunusedmaterialfromvariousprocessing

FORESTRY PRIMARY PROCESSING

ROUNDWOOD SAWN TIMBER CONSTRUCTION PRODUCTS

SECONDARY PROCESSING CONSTRUCTION

TIMBER RECYCLING

INTEGRATED SUPPLY CHAIN DIAGRAM

16

stagestobereusedastherawmaterialforotherhigher-valueproducts.AccordingtoEdwardSternhouseofInWoodDevelopments;thereistypicallyanaverageof70%wastagefromtheinitiallyfelledtreetofinalproduct,materialwhichclearlyhasbotheconomicandproductionpotential.Inprimaryprocessingalone,figuresavailablefortheBSWTimbersawmillinNewbridgeonWyeindicatea42%wastagefromroundwoodinputtosawntimberoutput12.Theharnessingofthismaterialenablesthetimberbeusedtoitsfullestcapacity,extractingmaximumvalueandcreatinghigherrevenuesfortheindustry,whichinturnwouldbereturnedtothelocaleconomy.

Suchanapproachrequiresaclearanalysisofwood-basedproducts,fromsawntimbertopaper-pulp,todevelopstrategiesforintegratedsupplychains.Productssuchaswood-fibreinsulationandcharcoalwouldbeabletoharnesstheby-productofprimaryprocessingbusinesses,butthisrequiresbothsufficientby-producttomaketherelationshipviable,aswellasthecloseproximityofthetwofirms.

Inadditiontothetargetofzero-wood-wastageforvirgintimber,theindustryshouldalsostrivetointegrategreaterquantitiesofrecycledtimberintothemanufactureofnewproducts.Thisbothcreatessignificantadded-value,butalsoactstocreateamoresustainableindustryasawhole.Thetimberpanelmanufacturer,Kronospan,currentlyusesabout60%recycledfibreintheirchipboardmanufacture,includingsawmillresidue,butwiththepotentialtoraisethistoaround80%14.

Overtime,theuse(andcorrectgrading)ofhome-growntimberwouldlifttheprimaryprocessingsector,whichinturncouldsupplyandbesupportedbyanalreadystrongsecondaryprocessingandconstructionindustry.

3.4FUTUREDEVELOPMENT

Thelong-termdevelopmentofanintegratedtimbersupply-chainrequiresthreecriticalfactors:

[1]Increasedcollaborationandcommunicationbetweenallsectors:

Thisisessentialforthedevelopmentandsuccessoftheindustryasawhole,andcoversalargerangeoffactorsincluding:• Educationprograms,bothwithintheindustry,andforarchitectsanddesignerswhospecifyconstructionproducts• Collaborativeresearchanddevelopment,leadingtonewproductsandproductionsystemsthatarebeneficialtotheentireindustry• Creationoflargersupplycompaniesthroughthenetworkingofsmallerorganizations.Thisparticularlyrelatestosawmillsandotherprimaryprocessorsasameansof

guaranteeinglong-termsecuresupply,modeledalongthelinesoftheBioRegionalCharcoalinitiative,throughwhichsmallregionalcharcoalproducerssupplynationalretailersunderasinglebrandname.

[2]Investmentinthelong-termevolutionoftheindustry:

Forestry,byitsverynature,isalong-termoperation.Trees,particularlyinlong-rotation,takeyearstogrowandmaturebeforetheyareharvested.ThedevelopmentofmoresustainableforestrypracticestoreplacetheexistingSitkasprucemono-cropplantationswilltakedecades,andrequiresgradualandlong-termchange.ThedevelopmentoftheWelshtimberindustryneedstotakeplacealongsidethis,requiringflexibilitywithinthesupplystream.

Therelianceonimportedtimberneednotbeathreattotheindustry,butratherameansofsupplyingandenablingthedevelopmentofprimaryandsecondaryprocessors,whilstadomesticsupply-chainisestablished.

[3]Focusonaddingvaluethroughthesupplychain,ratherthanjustincreasingthevolumeofoutput:

Giventherelativelysmallvolumeofsupplyandproductionwithintheindustry,itiscriticaltoaddvaluethroughoutthesupplychain,ratherthansimplyincreasingoveralloutput.Thiscanbedoneateverystageofthesupplychain,fromthemanufactureoftimbercladdingsystemsbyprimaryprocessors,thefabricationofmorecomplexbuildingproductswithinthesecondaryprocessors,throughtotheproductionoffurnitureandotherhigh-valuehigh-skillitems.

Addedvaluealsoincludesinnovativeusesofrecycledandpreviouslydiscardedmaterials.Examplesofthisincludestheuseofsmall-sectiontimberinwindowframesanddevelopmentofend-grainflooringbyCoedCymru15.ThereisalsothepossibilitytodevelopcontactswithorganisationssuchasBioRegionalmini-millsforsmall-scalepaperproduction,andBioRegionalCharcoal.

INWOOD DEVELOPMENTS, SUSSEXImagecourtesyoftheauthor

21

4.0Welsh+ImportedTimberPriceComparison

Theissueofcostcompetitivenessiscriticaltothedevelopmentofanyindustry.Forthevastmajorityofclients,architects,andcontractorsitistheprincipalissuethatmattersinspecifyingtimber,andfactorssuchasthelowerenvironmentalimpactofdomestictimberversusimportedtimber,althoughimportant,aretypicallylessofaconcern.

ForaquickanalysisweherecomparethepriceofspecifyingC16andC24timbers.Althoughthisdoesnotdirectlyrelatetodomestic/importedtimber,itisassumedtobecomparabletothedominanceofC16timbersupplywithinWalesandtheUK,andtherelativelackofC24.Clearlyfurtheranalysisisneededbasedoncoststhatareestimatedfromdomesticsawmillsandsuppliers.

4.3CONCLUSIONS

Itmustbenotedthattheseareveryroughcalculationsbasedonlikelycomparativefiguresratherthanactualfigures,despitethishowevertheyappeartoclearlyindicatethepricecompetitivenessofhighergrade(imported)C24timbers,basedonthesavingsgainedthroughthereductionofmaterialrequired.Savingscomingfromreducedlabourtimeandtimeonsitewouldfurtheremphasizethisresult.

Moreanalysisoncostcomparisonbetweenimportedanddomesticallysourcedtimberisclearlyrequired,howevertherecouldwellbeanargumentforgovernmentsubsidiesondomestictimber,orsomeotherfinancialbalancingmeasurethatcouldbelobbiedfortobenefitthetimberindustry,theconstructionindustry,andbroaderenvironmentingeneral.

4.1TIMBERPRICES(FromPremierForest)

C16(SC3): £180/m3C24(SC4): £195/m3

4.2C16+C24COMPARISON

C16(SC3): 50x195mm 450mmcenters 4mspan PotentialDomesticTimber 9.9mlengthbuilding =22timbers 0.858m3 =£154.44

C24(SC4): 50x195mm 600mmcenters 4mspan ImportedTimber 10.2mlengthbuilding =18timbers 0.702m3 =£136.89 11%cheaper

40m2building(asabove) C16 =£154.44 C24 =£136.89 11%cheaper400m2building C16 =£1,565.44 C24 =£1,277.64 18.4%cheaper

4,000m2building C16 =£15,605.46 C24 =£12,667.54 18.8%cheaper

22

5.0PotentialProductsandManufacturing

AspreviouslydiscussedoneofthestrengthsoftheWelshtimberindustryisthediversityofexpertise,suppliersandmanufacturersitencompasses,fromforestry,throughbothprimaryandsecondaryprocessing.AlreadytherangeofproductionoftimberproductswithinWalesissignificant,fromsmall-scalefurnitureandfencingproducers,throughtolarge-scaleindustrialisedfacilitiessuchastheKronospanwood-panelfactorynearWrex-ham.

Thepotentialexistsfortheproductionofafarwiderrangeoftimberproducts,which,ifconceivedaspartofanintegratedsupplyandmanufacturingchain,couldtransformtheindustryandhelpdevelopasustainableregionaleconomy.

Theirrangeofpotentialproductsisextensive;alimitednumberareconsideredonthefollowingpages.

5.1PrimaryProcessing:FingerJointing/CladdingSystems

Atitsmostbasic,valueaddedproductionoccursatprimaryprocessingstage,whereroundwoodbecomessawntimber.Withalittleextrainvestmentintimbergradingandfingerjointingmachineryitispossibletoproducehighervalueproducts,suchasstable,long-lengthcladdingsystems.

Finger jointed timber for long-length cladding mid-manufacture at Inwood Developments, Sussex

Image courtesy of the author

23

5.2StructuralSystems:LaminatedTimberBeams/Glulam/EndlessBeams

Comprisedoflayersofsmallsectiondimensionedtimber,bondedtogetherwithadhesiveunderheatandpressure,glue-laminated(glulam)beamsarerelativelystraightforwardtoproduce.Manufacturedwitheitherhorizontalorverticallaminates,theindividualtimbersaretypicallyfingerjoinedateachendtogivecontinuitytothelaminations,enablingtheproductionof‘endlessbeams’,withfewlimitationsonsize.Theautomationofthemanu-facturingprocesshasthepotentialtosignificantlyincreaseefficiencyandproductionspeed,resultinginafarmorepricecompetitiveproduct.

Theprimarybenefitsofglue-laminatedtimberbeamsaretheirstrength,dimensionalsta-bility,andlargesectionsizesandlonglengths,particularlyincomparisontotherelativelysmallsectionsthattheyarecompositesof.

5.3StructuralSystems:I-Joists

Comparedtosolidtimbersections,I-Joistsusesignificantlylessquantitiesofmaterial,andhaveahighstrengthtoweightratiosforequivalentlydimensionedsections.Typicallycomprisedofsolidtimberflangeswithorientedstrandboard(OSB)webs,theyarebothlightweightandmateriallyefficient.

GiventheextensiveproductionoforientedstrandboardintheUK,thepotentialforthedevelopmentandexpansionofdomesticI-Joistmanufacturingissignificant.ItshouldbenotedhoweverthatthetimberproductsmanufacturerJamesJones&SonshasinvestedsignificantlyintwoI-JoistplantsinForres,Scotland,andnowdominatethemarket.AsimilarinvestmentinWalesmaynowbeprohibitive.

Lightweight I-Joists installed in place of traditional solid timber joistsGlulam beams in use in the Sumika Pavilion by architect Toyo Ito

Image source: Flickr user karenandbrademerson, licensed under a creative commons licence 2.0Image source: Flickr user japanese_craft_construction, licensed under a creative commons licence 2.0

2�

5.4StructuralSystems:LadderTruss

Laddertrussesareatypeofparallelchordtrussutilisingstress-gradedtimberchords,pleatedtogethereitherwithtimber,orwithametalweb.AswithI-Joists,laddertrussesprovidealightweight,dimensionallystablealternativetosolidtimber,particularlywherethedimensionsrequiredwouldeitherbeunavailable,orcost-prohibitiveinsolidtimberform.TheopennatureoftheladdertrussalsoprovidesabenefitovertheI-Joistofbeingabletorunservicesdirectlythroughthestructure.

Theutilisationoflow-gradetimberinahigh-strengthproduct,alongwitharelativelysimplemanufactureprocess,ensuresthatthepotentialforthedevelopmentandmanu-factureofladdertrusseswithintheWelshtimberindustryissignificant.

5.5StructuralSystems:BoxBeams

SignificantresearchcapitalhasbeeninvestedinthedevelopmentofboxbeamsinWalesparticularlythroughtheWelshSchoolofArchitectureatCardiffUniversity,andthroughCoedCymru’sTyUnnosproject.Conceivedasastructuralsystemthatcanmakeuseofthelow-gradeSitkaspruceavailable,alongwithsimplemanufacturingprocessessuchasthoseusedforpalletfabrication,theboxbeamwasoriginallyenvisagedaspartofacom-pletepackagethatcouldprovideboththestructuralframeandasystemofinfillpanels.

SincedevelopedbytheconstructionanddevelopmentcompanyElementsEuropeasamodularpre-fabricatedsystem,theboxbeamhasclearmarketpotential.

Box Beams being assembled at the Welsh School of ArchitectureLadder Trusses used on bere:architects’ Larch House in Ebbw Vale, South Wales

Image courtesy of bere:architects Image source: Coed Cymru

2�

5.6SolidCoreSystems:CLTPanels

Cross-LaminatedTimber(CLT)isasolid-coreconstructionsystemthatenablesrapidcon-structiontimesduetolargepanelsizesandlimitednumbersofjoints.Thepanelsconsistofsinglelayerboards,eachboardmadeupofindividualplanksfingerjointedforstrength,withlayersofboardscross-laminatedwithadhesivesforbonding.Thecross-laminationandgluingensuresminimalshrinkageandsettlementovertime,withthehigherthermalmassofsolidcoreconstructionproducesgreaterthermalstabilitywhencomparedtostandardtimber-famingsystems.

ThemanufacturingprocessforCLTpanelsisrelativelycomplexhowever,requiringalarge-scaleautomatedproductionlinefortheplaning,sizing,gluing,layingup,andpressingofthepanels,withevenverticalandsidepressureappliedtoeachpanel.ThemanufactureofCLTpanelsandsimilarproductsalsorequiresconsiderablequantitiesoftimberwithguaranteedsupply,onascalethattheUKisunlikelytobeabletomeetatcurrentratesofproductions.

5.7SolidCoreSystems:Brettstapel

Brettstapelisasolidtimberconstructionsystemfabricatedfromlow-qualitysmall-di-mensionsoftwoodtimberpoststhatmaynototherwisebesuitableforconstruction.Connectedwithhardwoodtimberdowelsbrettstapelusesneithergluenornails,unlikeothersolidcoresystemssuchasCLTpanels,arguablyproducingabetter-qualityinternalenvironment.

Aswithallsolid-coreconstruction,brettstapelrequiresconsiderablequantitiesoftimber,andalthoughitmaybesuitableforlimitednumbersofprojectsinWalesandacrosstheUK,alarge-scaleimplementationisunlikelyduetolimitationsonthesupplyofdomestictimberavailable.

Prototype illustrating Brettstapel wall build-upCLT construction of the MK�0 tower by de Rijke Marsh Morgan Architects

Image source: Flickr user daisybush, licensed under a creative commons licence 2.0 Image source: http://www.brettstapel.org, © James Henderson

26

5.8PassivHausProducts:WoodfibreInsulation

Producedentirelyfromwoodfibre,andbondedfromthenaturaladhesivenessofthelinginresinwithinthewooditself,woodfibreinsulationisanentirelynaturalmaterial,andcanbeproducedfromthewastematerialofothertimberprocessing.Thepotentialforthedevelopmentofwoodfibreinsulationmanufacturingaspartofazero-wood-wastagestrategyissignificant,butinevitablydependentonquantitiesofproduction,andqualityofsupplyofwaste-woodasarawmaterial.

5.9PassivHausProducts:PassivHausWindows

High-valueproductssuchaswindowframesthatmakeuseofsmall-sectiontimberscouldproveparticularlyvaluabletotheWelshtimberandmanufacturingindustries.Thedevel-opmentoftheUK’sfirstPassivHauscertifiedwindowsforbere:architects’LimeHouseatEbbwVale,bytheValePassiveWindowPartnership-aconsortiumofWelshjoineryfirmsbroughttogetherbyWoodknowledgeWales-provedthepotentialforthemanufactureofhigh-quality,high-tolerancetimberproducts.

Section through PassivHaus certified window unitInstallation of woodfibre insulation

Image courtesy of bere:architectsImage source: Actis

27

6.0ExistingWelshTimberStudies

SeveralsignificantstudieshavealreadybeencompletedintothedevelopmentofWelshtimberanditiscriticalthatthesebeincorporatedintoanyfutureintegrateddevelopmentstrategy.ThesestudiesincludetheTyUnnosprojectbyCoedCymruandtheWelshSchoolofArchitecture,andthedevelopmentofcertifiedPassivHauswindowsforbere:architects’EbbwValePassivHaus.Inadditiontothese,itisworthconsideringtheoutcomesofprojectssuchasGATE-GainingAddedValueforTimberinEurope-,wheretheForestryCommissionWaleswasleadpartner,aswellaspossiblecollaborationwithorganisationssuchasthePrince’sFoundationfortheBuiltEnvironment,whichiscurrentlyundertakingastudyofregionalsupplychainsinWalesforanumberofconstructionmaterials,includingtimberandslate.

7.0CaseStudiesandBenchmarking

Thereareanumberofregionalandbusinesscasestudiesthatwouldbeusefultoanalyse,andbenchmarktheWelshtimberindustryagainst.Theseinclude:

7.1REGIONAL

VORARLBERG[AUSTRIA]ThewesternmostregionofAustria,Vorarlberghas,overthepast10years,becomeasignificantcentreforthedevelopmentandproductionofhigh-qualitylow-carbontechnologies.InordertodevelopasimilarregionalspecialtywithinWalesitiscriticaltounderstandtheVorarlbergmodel,andhowitdeveloped,toseeiftherearelessonsorexperiencesthatcanbeappliedtoWales.

7.2BUSINESSANDTRAININGFACILITIES

INWOODDEVELOPMENTS[SUSSEX,UK]Aprivatemanufacturingfacility,InWoodDevelopmentsproducesglulambeamsandhigh-qualitytimbercladding,alongwithanumberofothertimberproducts.Theyspecialiseinfingerjointedtimberandhavethelargestfinger-jointingfacilityintheUK.

KRONOSPAN[WREXHAM,UK]BasedinChirknearWrexham,thewoodpanelmanufacturerKronospanisoneofthetop10manufacturingcompaniesinWales,employingover600people.AllofKronospan’sproductsaremadefromdomestically-sourcedtimberandincludesignificantquantitiesofrecycledtimer.AspartoftheAustrian-basedKronospanWorldwide,Kronospancollectivelyistheleadingmanufacturerofpaticleboard,mediumdensityfibreboardandorientedstrandboardglobally.

SMARTLIFECENTER[CAMBRIDGE,UK]SmartLIFEandtheSmartLIFELowCarbonCenter(tobeopenedOctober2011aspartofthehiveenterpriseandeducationpark),isajointcollaborationbetweenCambridgeshireCountyCouncilandCambrigeRegionalCollege,toteachskillsneededforbuildinglowcarbonhomesandinstallingrenewableenergysolutions.

28

References

2.0 WELSH FORESTRY

1 Smith, Steve, and Justin Gilbert. National Inventory of Woodland and Trees: Great Britain. Forestry Commission, Edinburgh, 2002. p.10

2 Directorate-General for Agriculture and Rural Development. The EU Forest Action Plan 2007- 2011. European Commission, 2011. p.6

3 The Welsh Assembly Government. Woodlands for Wales. Forestry Commission Wales, 2009. p.11

4 Directorate-General for Agriculture and Rural Development. p.6

5 Smith, Steve, and Justin Gilbert. National Inventory of Woodland and Trees: Wales. Forestry Commission, Edinburgh, 2002. p.10

6 Smith. National Inventory of Woodland and Trees: Great Britain. p.59

7 Ibid. p.10

8 Jones, Carwyn. Foreword to: The Welsh Assembly Government. Woodlands for Wales: The National Assembly for Wales strategy for Trees and Woodland. Forestry Commission Wales, 2001. p3

9 Smith. National Inventory of Woodland and Trees: Wales. p.10



12 Ibid. p.10

13 The Welsh Assembly Government. 2009. p.11


15 Ibid. p.19

16 Ibid.

17 Ibid. p.30

18 Ibid. p.10

19 Bell, Simon Crossplan: Integrated, participatory landscape planning as a tool for rural development. Forestry Commission, Edinburgh, 2003. p.12



22 Ibid. p.28

23 Ibid. p.63

24 Forestry Commission. Sale Volumes 2010-11. Web. n.d. 28.01.11. http://www.forestry.gov.uk/ forestry/infd-832mjh

25 Ibid.

26 The Welsh Assembly Government. 2009. p35


28 Jones, Dennis. Summary Report 3:2010. “Timber Grading”. Woodknowledge Wales, 2010. p1

29 Ibid.

30 The Welsh Assembly Government. 2009. p.16

3.0 SUPPLY CHAIN


2 Jaakko Poyry Consulting. Welsh Forest Industry: Mapping and Benchmarking the Forest Industry – Final Report (Executive Summary Only). London, UK; 2004. p8


4 Jaakko Poyry Consulting. p7

5 The Welsh Assembly Government. Woodlands for Wales: The National Assembly for Wales strategy for Trees and Woodland. Forestry Commission Wales, 2001. p27


7 Department for Communities and Local Government. “Building a Greener Future: policy statement”. British Government, Department for Communities and Local Government: London, July 2007. p5. Pdf. 19 Nov. 2010


9 Ibid.



12 BSW Timber >> Locations >> Newbridge. BSW Timber. Web. n.d. 26.03.11.

13 “Boardmaker claims ‘massive potential’ for recycled wood’. letsrecycle.com. Web. 28.07.06. 02.03.11.


Documents

INTEGRATED STRATEGIES FOR THE WELSH TIMBER INDUSTRY · One of the most significant factors influencing the development of theWelsh timber industry is the relatively low quality of