LAMINATED VENEER LUMBER Scaffold plank from Russian renewable wood sources MLT LTD. PLANT IN THE TOWN OF TORZHOK 60 000 T 250 000 m³ 150 000 m³ MLT Ltd. plant designed for Annual design capacity of Annual capacity of wood production of Ultralam LVL is the plant is 150 000 cubic pellet line is 60 000 tons. the largest production of this meters of LVL and could be kind in Europe commissioned boosted up to 250 000 cubic in the year 2009. meters. 24ht 600 400 000 m³ Territory of MLT plant equals Area of main production At present 600 employees to 24 hectares. premises is 400 000 square are working for MLT. meters. 2 • MLT PLANT TOPplank EQUIPMENT SUPPLIERS The plant boasts unique • Evergreen Engineering, 60 meters press designed USA – engineering by Dieffenbacher for services continuous LVL production. This means unlimited length • Dieffenbacher, Germany of LVL beams that are cut – continuous press used depending on the demands to glue several plies of of our customers and veneer. transport conditions. • COE, USA – veneer peeling line. Production utilizes advanced technology of continuous pressing with • CTC, USA – lay-up and microwave pre-heating which billet processing lines. enhances resin propagation into the wood fibers and • SGS, Austria - equipment creates new, uniform high- installation. strength material. UNIQUE 60 METERS PRESS � TOPplank MLT PLANT • 3 PRODUCTION Modern high-tech wood processing techniques are utilized in production of Ultralam laminated veneer lumber. Such approach makes possible to double the advantages attributable to the solid timber and mini- mize its disadvantages. MLT has its own log yard which area allows to store up to 40 000 cubic meters LOG YARD � of logs. Raw materials (pine and spruce) delivered to three cutters. The slasher veneer recovery. the mill are sorted against trims the logs at the ends species, quality and size at Veneer ribbon is delivered and cuts them into 2.65 m semi-automatic Hekotek line to the clipper along the ac- peeling blocks that proceed (Estonia). celeration conveyor. Comput- to the peeling line. erized video control system From the log yard the logs Blocks peeling and clipping available at the peeling line are fed to debarking line. of 3.2 mm thick veneers is detects both veneer defects Debarking, conditioning and performed at high speed line in the ribbon and pattern of sawing of raw materials are supplied by COE Manufactur- ribbon clipping to the re- performed at the line sup- ing Company, USA. Produc- quired sizes. Scanner system plied by Vitech Engineering, tion capacity of the line is reveals veneer defects Inc. (Canada). up to 18 blocks per minute. during clipping process what Conditioning of coniferous COE line is equipped with precludes their presence in raw materials is performed a special set of supporting veneer sheets loaded into in through-type conditioning rolls providing the peeling the dryer. ponds for the time period down to 90 mm cores. Such Control system reads the from 24 to 36 hours, at 50- cores and defect veneer are moisture content value and 80°C. Primary function of diverted on special conveyor calculates average or maxi- conditioning process is heat- and then chipped and used mum moisture content for ing up of wood to make it at pellet production. each sheet. The same value softer and increase its work- is used to determine the av- ability prior to peeling. When delivered to the peel- ing line, the block is scanned erage moisture content when The logs are then unloaded by laser beams. Scan data veneer is graded against onto the chain conveyer that is communicated to the spin- moisture content. takes them to the slasher, dles which assure optimum Veneer is dried in a 6-level a pendulum disc saw with block positioning and highest roller-type thermal oil dryer 4 • PRODUCTION TOPplank HIGH SPEED PEELING LINE � Germany by Grenzebach BSH. The air is circulated inside the dryer until it reaches certain humidity. Air temperature inside the dryer sections may be up to 192°C. From the dryer outfeed ve- neers are taken to the sort- ing conveyor. Veneer tester «Metriguard» determines the density of dry veneer sending THERMAL OIL DRYER � ultrasonic signals and meas- uring the signal propagation time in the veneer. Denser defect clipping and composing line. Hashimoto Denki Co (Japan) the veneer, the quicker ultra- composing line is designed to compose full-size veneer sheets sonic wave travels through out of random veneers or veneer pieces. All defects are clipped the sheet. Veneer is sepa- out prior to composing. rated by 4 grades based on the density measurement Composed sheets with longitudinal orientation of grain are fed results. A-class veneers to the scarfing line and further to the lay-up system. are used for structural LVL Lay-up of the billets is made at Corvallis Tool Company (CTC) manufacturing. automatic line. For the moment this is the quickest line of this Full-size veneers proceed kind with 2 levels. Line speed is 54 sheet counts per minute and to the scarfing line, random if necessary could be increased up to 81 sheet count per minute. and defected veneers – to TOPplank PRODUCTION • 5 conveyor and passes through metal detector which pre- vents ingress of metal parts into the microwave unit. In the continuous press LVL billet is conveyed with con- stant speed through several zones with different tempera- ture and pressure settings where it is densified to the required thickness. Pressing temperature is 185°C. When the billets exit con- tinuous press, they pass VENEER GRADING LINE � through the blow detector and thickness meter; then the billet sides are hogged Different patterns are used forks place the sheet onto to final dimension and it is to make type I and II boards. the conveyor. Then the pack- cut by diagonal saw to the Thickness range of the bil- age is moved to the shuttle length required. Billet stacks lets varies from 21 to 100 which takes it to the press are taken to the storage mm. Lay-up of Type I means infeed section. where they are kept for at that all veneer sheets have Veneer fan is continuously least 24 hours. After the hold parallel orientation of grains. formed on the lay-up line time the billets are cut at rip In type II lay-up veneers with and conveyed to the micro- saw. parallel orientation of grains wave pre-heater incorpo- are combined with cross- Sound boards are conveyed rated into the hot press. Pre- band veneers in predeter- to the packaging line where heating and hot pressing is mined sequence. they are first marked with done in Dieffenbacher press plant logo and other special Phenol-formaldehyde glue (Germany). Continuous mat information. The stack of LVL with high water resistance of LVL travels along the belt boards is accumulated. Auto- and low emission class is used for LVL production. The glue is applied through the curtain coater located crosswise the lay-up line. The glue is pumped to the curtain coater from both sides. Veneer sheets with glue spread proceed to the lay-up section. Lay-up section consists of 2 levels, each one equipped with internal and external groups of forks. While the inner forks load veneer, outer AUTOMATIC LAY UP LINE � 6 • PRODUCTION TOPplank matically LVL stacks are cut by length, edges are squared, the boards are wrapped into special PVC film and banded with metal strap. Packed bundle is placed into the bil- let warehouse. Finished products are tested at MLT QC lab. Testing equipment available at the lab allows to measure basic physical and mechanical properties of the product, PRESS � as well as its density. PRODUCTS ARE TESTED � WAREHOUSE � TOPplank PRODUCTION • 7 TOPplank IS A STRONG AND LIGHT LVL SCAFFOLD PLANK The structural uniformity of • In the chemical industries LVL combined with the strict and marine applications for quality control of all process- corrosive environments es of manufacture ensures TOPplank is safe and for pur- • Where the electrical insula- pose as scaffold planking. tion properties of TOPplank are another safety advantage The superior technical char- • Where sparks arising from acteristics of TOPplank make metal on metal contact may it ideal for use in place of present a hazard for safety other LVL scaffold planks and ordinary timber planks. Use • Where the scaffolding lay- of TOPplank is also advanta- out precludes use of modular geous: system TOPplank INCLUDES: • Individually proof tested • Stamped as “scaffold plank” • 100% renewable Russian spruce and pine • Excellent structural rigidity • Strong and long lasting • Predictable strength • Customer specific edge branding • Lightest in weight • Enhanced durability and safety • Perfect for petrochemical and gas industries • Meets all industry standards • Anti-corrosive and chemical properties 8 • ABOUT TOPPLANK TOPplank SPECIFICATION • TOPplank scaffold plank or any customer’s trademark • End sealer retards moisture entry • OSHA proof tested • Production date • Country of origin GENERAL SIZES: THICKNESS: WIDTH: LENGTH: 21-100mm till 1250mm till 20500mm TOPPLANK SIZES: THICKNESS: WIDTH: LENGTH: 38 mm 225, 230, 235, 3900 mm 42 mm 300 mm 5900 mm And any other And any other And any other under request with under request with under request with tolerance +/-1mm tolerance +/-2mm tolerance +/-5mm TOPplank ABOUT TOPPLANK • 9 TOPplank LOAD RATING MAXIMUM SPAN 75 psf (HD) 10’ SCAFFOLD 1 Person 10’ SPAN 2 Person 10’ TABLES 3 Person 7’ NUMBER OF PLIES AT 39 MM THICK SCAFFOLD PLANK Plies TOPplank is homogeneous characteristics is a result of every thickness beginning with superior strength prop- combination of best quality with 38mm (14 veneer plies erties and is proof-tested to raw materials, high-tech instead of 13 for the thick- ensure compliance to the equipment and brand new ness 38mm and 15 veneer OSHA and ANSI A 10.8- production technologies.