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Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018 West Lafayette, IN

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Page 1: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

Potentialandlimitationsofusinghardwoodlumberasrawmaterial

forCLT.

HenryQuesada,BrianBond,Sailesh Adhikari

2018WestLafayette,IN

Page 2: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

Agenda

• Marketsforwoodproducts• CLTproductionprocess• ResearchonhardwoodCLT• ChallengesanddriversforhardwoodsCLT• Finalthoughts

Page 3: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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

Page 4: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

Marketsforwoodproducts

• Impactsonenergyandglobalwarmingpotentialis16%and31%lesswhenusingtimberinsteadofconcrete.

• Energyandglobalwarmingpotentialis17%and26%lesswhenusingtimberthansteel.

http://www.themostnaturalresource.com/green-building/

Page 5: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

Cross-laminatedtimber(CLT)

• ANSI/APAPRG320-2012 :Aprefabricatedsolidengineeredwoodpanelmadeofatleastthreeorthogonallybondedlayersofsolid-sawnlumberorstructuralcompositelumber(SCL)thatarelaminatedbygluingoflongitudinalandtransverselayerswithstructuraladhesivestoformasolidrectangular-shaped,straight,andplanetimberintendedforroof,floor,orwallapplications.

Page 6: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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

Page 7: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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.

Page 8: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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.

Page 9: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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.

Page 10: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

• 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.

Page 11: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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

Page 12: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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

Page 13: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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

Page 14: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

ChallengestostartoutCLTproduction

Productionsetup

LackofCLTmarkets

RawMaterials supply

Vertical integration

CLTcodeacceptance

CLTknowledge

Success

Profits

Manufacturers’perspective:

Page 15: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

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

Page 16: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

CommercializationBarriersofCLTs

Buildingregulations

Fireproofacceptance

Shippingandlogistics

Currentproductioncapacity

CLTadvantagesnotknown

Comm.from/toarchitects

NeedpolicyforCLT

Successfulcommercialization!

?

?

?

?

??

?

-Outsideeurope-Containershippingislimited

-Norelevantmfg capacityintheUSA-Europeancapacityisbookedfor8months

-FireproofengineersinEuropestillquestionCLT

-UseofCLTinpublicbuildings-Designto

manufacturingflowofinformationneedstobeimproved

-Engineers-Architects-Generalpublic-Government

-Buildingcodes

Page 17: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

Finalthoughts

• BarriersandchallengesimpactingthesuccessofCLTmanufacturingandcommercialization

Markets

Manufacturingtechnology

Logisticsoperations

PerformanceofCLTsystems

Informationflow

Educationalactivities

Verticalintegration

Rawmaterialsupply

TheCLTdorm-buildingattheUBCcampus

Page 18: Potential and limitations of using hardwood lumber …...Potential and limitations of using hardwood lumber as raw material for CLT. Henry Quesada, Brian Bond, Sailesh Adhikari 2018

• Acknowledgements– OmarEspinoza,UM– DanHindman,VT– BobSmith,VT– USDA/WoodInnovationgrants– SothernExportCouncil– USDA/NIFA