Mass Plywood Panels: Designing with the Newest Mass Timber Structural Product

Presented by Eric Ortiz, Freres Lumber Co., Inc.

Disclaimer: This presentation was developed by a third party and is not funded by WoodWorks or the Softwood Lumber Board.

4/20/18 1 • “The Wood Products Council” is a This course is registered with AIA CES for Registered Provider with The American continuing professional education. As such, it Institute of Architects Continuing does not include content that may be Education Systems (AIA/CES), Provider deemed or construed to be an approval or #G516. endorsement by the AIA of any material of

• Credit(s) earned on completion of this construction or any method or manner of course will be reported to AIA CES for handling, using, distributing, or dealing in AIA members. Certificates of Completion any material or product. ______for both AIA members and non-AIA Questions related to specific materials, methods, and members are available upon request. services will be addressed at the conclusion of this presentation.

4/20/18 2 Course Description Mass plywood panels (MPP), a veneer-based engineered wood product, are a recent addition to the mass timber line-up of product options. This presentation will introduce MPPs with an outline of the manufacturing technologies, testing and certification that led to their development, followed by an in-depth look at the applications and requirements associated with their use. Topics will include methods of structural design, code compliance, product size options, and availability.

4/20/18 3 Learning Objectives

• Discuss the composition of mass plywood panels and the veneer-based manufacturing technology that led to their development. • Highlight testing completed and certification received to date for mass plywood panels. • Demonstrate options for the use of mass plywood panels in construction, including wall, floor and roof systems. • Review methods of structural design available to designers to aid in mass plywood panel projects.

4/20/18 4 • FLC Operates • Two Veneer plants • Veneer Drying Facility • Plywood Plant • Cogeneration Facility • Stud mill • Fleet of Log and Highway Trucks • MPP Facility • Operational December 2017

4/20/18 5 Our Raw Material is Veneer Veneer is the finest wood format to create engineer wood products • Higher Recovery of usable fiber than lumber • Overcomes the problem of producing a square product out of a round tree • Innumerable potential layups with various thicknesses, density grades, orientations and visual grades Timber Availability • Ideal timber for engineered veneer products is suppressed 2nd growth trees • Average block diameter for our engineered veneer plant is 8.5” • EVERY sheet of veneer has a definable engineering value

4/20/18 6 Structural Composite Lumber 1.8E Lamella Example • 9-plies of veneer • 7 long-grain & 2 cross grain • Veneer density grades include G1, G2 and G3 Layup Benefits • Majority of panel is long-grain orientation • Span Performance • Cross-banding contributes to minor force direction and panel dimensional stability • Primarily used in Tension and Compression Portions of Mass Timber Panel

4/20/18 7 Structural Composite Lumber 1.0E Lamella Example • 9-plies of veneer • 5 long-grain & 4 cross grain • Veneer density grades predominantly G3 Layup Benefits • Alternating Long and Cross-grain veneers • Major Force & Minor Force Direction Contribution • Shear performance & Panel Stability • Primarily used in Center portion of Mass Timber Panel

4/20/18 8 4/20/18 9 MPP- Design Values

4/20/18 10 Scarf Joint

4/20/18 11 30-Piece unit of 4’ x 48.5’ x 1” billets ready for the secondary lay-up.

4/20/18 12 MPP Manufacturing • Pre-made 4’ wide by 48.5’ long billets - structural composite lumber • Panels built predominantly in long lamellas- overlapping joints to eliminate weakness across the panel width • Cross-laminations can be built into the panel per design specifications • 54 veneer plies in a 6” thick MPP panel, each engineered for appropriate density, orientation, and visual grade • Cross-banding built in through the panel- NO ODD PLY BENEFIT

4/20/18 13 Mass Timber Panel Facility Operational December 2017

4/20/18 14 Product Strengths Cross-banding in Each 1” Lamella • Panel Thickness Increased in 1” increments • NO ODD-PLY BENEFIT • Not only is the MPP panel engineered but also each individual lamella is engineered as well. Density • Potentially Stiffer Performance Cost • Density graded veneers of lower grades widely available • 95% of full sheet veneer processed at our green-ends are G3 or above Patent Pending • Product & Process Patent Pending • PCT Patent Pending for International Application

4/20/18 15 Product Weaknesses Glue-lines • Intense QC to ensure bond-quality • Number of glue-lines per cross-section Wood Loss • 10% wood loss in structural joint • Increased fall-down for SCL lamella Certification • Multiple Steps for Certification • EXPENSIVE FOR MATERIAL AND TESTING • ASTM D5456- Creep Testing • Long-term testing • 1st time this testing protocol has been applied for a Mass Timber Panel Unique • No template for facility design and application • No existing tested information for comparable product

4/20/18 16 Product Certification: APA-EWS and ICC-ES

• Structural Composite Lumber: ASTM D5456 • ASTM D5456 – 14b “Standard Specification for Evaluation of Structural Composite Lumber Products” • ICC-ES AC 47 – “Structural Wood Based Products”. • Certification of the MPP Products • ANSI/APA PRG 320-2018 – “Standard for Performance- Rated Cross-Laminated Timber” • ICC-ES AC 455 – “Cross Laminated Timber Panels for use as Components in Floor and Decks”

4/20/18 17 Testing Data Completed

1.8 E Design Values • Edge Bending with moisture and volume effects • Flat bending (both strength axis) 1.55 E Design Values • Tension with moisture and volume effects • In-process • Compression parallel to grain OSU bending and shear test data. • Duration of Load / Creep test (cross-banded) • Brochures based upon this data. 1.0 E Design Values MPP Testing • Flat bending • 2” shear and pre-qualification testing 2.0 E Beam and Header finishing/completed. • Duration of Load / Creep test (parallel lay-up)

4/20/18 18 Testing Underway • Lifecycle Assessment • Rocking Wall • Acoustics • Seismic Structures • Fastener, Dowel, Component Wall Test Future Testing • Large-scale Column & Beam • Compression Testing • Long-term Durability & Weathering • MIC-MAC

4/20/18 19 Southwest Research Institute- Fire Compartment Test

4/20/18 20 4/20/18 21 4/20/18 22 90,000 lbs. D-8 Caterpillar bulldozer on 4’ X 40’ X 12” panels,

4/20/18 32’ span, 4.5” of deflection. 23 4’ X 40’ X 10” panels, 28 foot span, 5” of deflection. 4/20/18 24 QUESTIONS?

This concludes The American Institute of Architects Continuing Education Systems Course

Eric Ortiz, MPP/Plywood Sales

Freres Lumber Co., Inc.

Email: [email protected]

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