The Coed Y Brenin Visitor Centre Extension - a Case Study
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Wales Forest Business Partnership Unit 6, Dyfi Eco Park, Machynlleth, Powys SY20 8AX Telephone: 0845 456 0342 Fax: 01654 700050 Email:[email protected] woodknowledge www.woodsourcewales.co.uk WALES The Coed y Brenin visitor centre extension - a Case Study woodknowledge WALES The Coed y Brenin visitor centre extension - a Case Study Britain’s first Brettstapel building constructed using homegrown softwoods, the extension to the Coed y Brenin visitor centre, was completed in summer 2013. The design process to this achievement started in autumn 2010, when ‘Eco-minimalist’ architects Architype were appointed by Forestry Commission Wales (FCW) to design an exemplar building utilising Welsh grown softwoods. Figure 1: Architype’s exploded sketch of the new extension (image: courtesy Architype) The site for the extension is located in difficult terrain, lamellae together to form structural panels. Hardwood cut into a bank and with limited access for heavy dowels ‘super’ dried down to around 6-8% moisture machinery. Mass concrete was specified for the walls of content (MC) can be used with lamellae of considerably the smaller room in the basement and Brettstapel for higher MC so that dowels absorb moisture from lamellae the two side walls of the larger basement room. On the thus expanding and locking them together. Several upper ground floor above the basement, Brettstapel was lamellae are clamped together and drilled right through specified for all walls except the south facing front wall at right angles using an auger 0.5mm smaller than the which is mostly glazed curtain wall supported on a glulam dowel finished size. Dowels can be inserted simply with frame. a heavy hammer. To speed up the process hydraulic or pneumatic equipped assembly lines are used. Lightweight timber frames called ‘Larsen trusses’ (Holladay, 2011) for holding insulation layers within an This type of panel is anisotropic and behaves in a similar outer sheathing panel were specified to be fixed over manner in expansion as would a large panel cut from the OSB sheathing on exterior face of Brettstapel walls. solid timber, it is unlike cross laminated timber (CLT) ‘Warmcel’ cellulose fibre insulation could then be blown panels which are restrained like plywood by the cross- into the void created by the trusses between sheathing tying action of orthogonal layers. However, because of panels. A 215mm deep Brettstapel floor is supported by the parallel alignment of lamellae (and therefore fibres) a whitewood glulam beam running north-south down the Brettstapel panels may perform better structurally centre of the basement. than CLT both as diaphragms and shearwalls; under compression Brettstapel can take up to twice the loading Brettstapel, literal translation ‘stacked planks’, is a type of similar sized CLT panels (Smith, 2013). of solid wood panel pioneered in Germany which uses either nails or wooden dowels to fix parallel softwood page one Figure 2: A Brettstapel house by Kaufmann; with the render Figure 4: Sohm’s distinctive wavy lamella profile, top surfaces finish it looks like a masonry structure showing machined shadow gaps At the moment Brettstapel is mostly manufactured Merkle sum up the situation thus; ‘stacked planking’ is in Germany, Austria and Switzerland; Merkle Holzbau an ecological system of construction which although in <http://www.merkle-holzbau.de> and Kaufmann of its infancy, is nevertheless technically perfected (Merkle Oberstadion http://www.kaufmannbau.com> are typical GmbH, 2013). Professor Kurt Schwaner of Biberach German Brettstapel manufacturers. Kaufmann started out University agrees and adds that even in Germany as a small carpenter’s workshop and grew to a vertically there is still some inertia in utilising Brettstapel which integrated company which processes local softwoods he explains as being caused by the high regard in using state of the art technology to create complete which masonry construction is still held. He also sees houses and municipal buildings. Two examples are shown; German carpenters and timber manufacturing SMEs as a newly completed Brettstapel house (Figure 2) and a conservative and somewhat reluctant to embrace new large two storey Brettstapel kindergarten (Figure 3). techniques (Schwaner, 2012). Nevertheless, specifiers in Britain have expressed great interest in the product; three Scottish architects, Sam Foster, Matt Bridgestock and James Henderson manage the website www.brettstapel.org where useful technical information and links can be found. One of the best known manufacturers are Sohm who are based in Austria <http://en.sohm-holzbau.at/>; their distinctive wavy lamella profile is shown above (Figure 4) and sides of panels showing dowel ends below (Figure 5). Figure 3: A Brettstapel kindergarten by Kaufmann, outer Figure 5: The sides of Sohm panels showing dowel ends timberwork being added page two During winter 2010-2011 Dennis Jones of BRE Wales for Forest Research) was warning of high distortion rates and George Mikurcik of Architype sought Welsh SMEs encountered in drying UK grown Sitka spruce. In order willing to create prototype Brettstapel panels in to minimise risk to the project the decision was made homegrown timber, however by summer 2011 only one between Architype, FCW and WKW to specify Douglas firm had shown interest and no practical tests had been fir lamellae; TRADA rates this species as showing ‘small carried out. Therefore Woodknowledge Wales (WKW) moisture movement’ (TRADA, 1999) making it one of the commissioned Dainis Dauksta to undertake research more stable homegrown softwoods for kiln drying. and prototyping work in partnership with Edinburgh Larch was also considered amongst other species; Napier University’s Centre for Offsite Construction and however with little knowledge of distortion Innovative Structures. characteristics during drying the idea was dismissed. Figure 7: Distorted larch down centre of picture sitting on much wider, stable Douglas fir board In spring 2012 Pochin’s PLC were appointed as main contractor and Architype were in discussions with their Figure 6: The first dowelled Brettstapel panel in British preferred Brettstapel sub-contractor. Dainis Dauksta had homegrown timber at ‘Timber Expo’ spent five days with researchers from Strathclyde and Napier Universities visiting Brettstapel manufacturers in One year after the design stage of the Coed y Brenin southern Germany, Austria and Switzerland. This study project commenced the first dowelled Brettstapel panel tour was organised under the auspices of ‘Limesnet’, an using homegrown spruce lamellae was produced in academic working group assembled by Dr Pete Walker of September 2011 and exhibited the same month on Napier Bath University. The study group were advised by Peter University’s stand at Timber Expo (see Figure 6, above). Kaufmann (of Kaufmann GmbH, Oberstadion, Germany) that they used softwood at 15% ± 2% MC for their Tenders to potential main contractors should have gone Brettstapel panels (Kaufmann, 2012). out by autumn 2011 to allow a start on site in spring 2012 but site problems delayed the process. By this time it It was becoming clear that German firms preferred to was known that around 100 square metres of Brettstapel install Brettstapel at a higher MC than UK architects would be required. Specifications were originally drawn and researchers had assumed would be necessary. up by Architype based on those of Austrian Brettstapel By machining shadow gaps into lamellae, subsequent manufacturer Sohm Holzbautechnik which included the lamellae shrinkage could be disguised. Scottish moisture content (MC) of 12% for spruce lamellae. architect Sam Foster was invited to advise on detailing of Brettstapel installation because of his previous This low target MC for spruce was considered to be a experience in project managing construction of Acharacle significant technical challenge considering that spruce Primary School in Scotland where imported Brettstapel is generally kiln dried to around 20% MC in the larger Figure 5: The sides of Sohm panels showing dowel ends panels made by Sohm Holzbautechnik had been used. sawmills and researcher Dr Barry Gardiner (then working page three A workshop was held at Architype’s office This decision was made because Sohm Holzbautechnik on April 3rd 2012 to discuss the following have a patent application for use of ‘dovetailed’ or angled dowels in Brettstapel panels. Therefore if the topics: patent is granted, any Brettstapel manufactured with dowel angles between 15° and 45° would infringe Sohm’s ● options for sourcing the timber, subcontractor own rights. Because orthogonal dowels were assumed to sourced or FCW donated to project: time and cost impart little racking strength to Brettstapel wall panels, implications 18mm OSB sheathing was specified by the architects to be fixed to the outer non-visual side of these panels. This ● choice of sawmill, their ability to adjust saws and would also act as an airtightness layer. cutting patterns to suit the project specifics Discussions between Pochin and Architype’s preferred ● recommended species for lamellae and dowels sub-contractor were not proving very productive, therefore there was considerable doubt regarding ● permitted number of knots, visual grading procurement of Brettstapel made with homegrown timber; not because of technical challenges, but rather ● moisture content of lamellae and dowels because of the nature of the contract. Under the selected form of contract (JCT intermediate) it was ● sizes of lamellae and