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