F SQM 7, pdf FOREX INC: COMPLEXE ABOUTAGE PLANT OPERATING STANDARD Prepared by FORINTEK CANADA CORP. Eastern Laboratory 800 Montreal Rd. Ottawa, Ontario K1G 3Z5 January 1984 ID=2247 2247 1983-84 Forei Inc. Forei standard. plant Inc. coipleie operating aboutage; : -A TABLE OF CONTENTS Page GENERAL PLANT AND END PRODUCT DESCRIPTIONS 1 FLOW PLAN AND MACHINERY DESCRIPTION 3 Tilt Hoist/Sizer 3 Defect Trim Saws 3 Dual Fingerjoint Shaper 3 Hot Air Oven 5 Glue Applicator 6 Assembly Machir 6 Flying Cut Off 7 Discharge Unit 7 Curing Table 7 Final Planing 7 JOB DESCRIPTIONS AND RESPONSIBILITIES 8 Tilt Hoist/Sizer Operator 8 Defect Trim Saw Operators 8 Fingerjoint Shaper Operator 9 Sorter/Stacker (pre-oven) 9 Aligner (pre-glue applicator) 10 Glue Applicator Operator/Mixer 10 Assembly Operator 11 Cut Off Saw Operator 11 Planer Operator 12 Line Supervisor 12 Millwright 14 Licensed Lumber Grader 15 i P&r~e QUALITY CONTROL DUTIES- General Bendi Tests Delans . tion Tests Wood Failure Tests QUALITY CONTROL TEST EQUIPMENT Bending Test Apparatus Laboratory Drying Oven Autoclave Moisture Meter GLUE STORAGE AND MIXING 23 Storage 23 Mixing 23 FINGERJOINT SHAPER MAINTENANCE Hydraulic System 24 ' Pressure Heads 24n • Cutterhead Knives and Saws Feed Chain Back Up Lugs ^ 0 Lubrication Schedule 23 APPENDIX 1 - Plant Reporting Forms APPENDIX 2 - Glue Manufacturers Specifications APPENDIX 3 - Report on the Calibration of Aluminum Bar li LIST OF TABLES ' Page TABLE Allowable Bending Stresses 26 LIST OF FIGURES FIGURE 1 . Forex Inc: Complexe Aboutage 27 Plant Layout FIGURE 2 . Forex Inc: Complexe Aboutage 28 Organization Chart GENERAL PLANT AND END PRODUCT DESCRIPTIONS This plant operating standard outlines the manufacturing and quality control testing of fingerjointed lumber at Forex Inc (Complexe Aboutage), 3100 boulevard Industriel, Val'd'Or, P.Q. The plant utilizes the Western Forest Produces Laboratory (WFPL) Pre-heated Fingers Method for curing the glued finger joints. The input lumber for the manufacture of fingerjointed stock consists of utility and better rough 2 x 4 in lengths of 3 to 1C '•et. The raw material, made-up of the spruce, pine and fir (S-?-F) -ies, is obtained or purchased (when required) predried tc • tandarc ~ o : re content (19%) from Forex or other sawmills. The fingerjointed material is produced and assessed following the criteria of NLGA Special Products Standard for Fingerjoined Structural Lumber SPS 1-81. The spruce-pine-fir species coroination fingerjointed lumber is manufactured for the following NLGA product grades only: A) " STUD" Grade - according to paragraph 121, NLGA Standard Grading Rules for Canadian Lumber. B) " CONSTRUCTION" LIGHT FRAMING Grade - according to paragraph 122b, NLGA Standard Gracing Rules for Canadian Lumber. C) " STANDARD" LIGHT FRAMING C-r&ae-accorcing to paragraph 122c, NLGA Standard Grading Rules for Canadian Lumber. D) " UTILITY" LIGHT FRAMING Grade - according tc paragraph 122d, NLGA Standard Grading Rules for Canadian Lumber. They shall be planed, visually graded and manually stamped. T Samples will be tested for bending strength, délamination resistance, and wood failure. All bending strength values will meet or exceed the requirements based upon Construction Grade (750 psi), although lower grades (based on visual grading) will also be produced (Table 1). Phenol Resorcinol Adhesive consisting of Cascophen LT-75 liquid resin and Catalyst FM-282FJ powdered hardener shall be used for the gluing of the fingerjoints. The mixing of the 2 components and the usage of the glue shall be according to Borden Chemical Western (Vancouver, B.C.) who is the manufacturer of the binder. The official certification and inspection agency of the plant is the Quebec Lumber Manufacturers Association (QLMA), Suite 200, 3555 boulevard Hamel ouest, Québec, P.Q. G2E 2G6. Forintek Canada Corp., Eastern Laboratory, 300 Montreal Road, Ottawa, Ontario, K1G 3Z5 is the official third party who ensures that all of the plant's testing equipment and procedures are accjrate. 2 FLOW PLAN AND MACHINERY-DESCRIPTION The general flow plan for our fingerjointing plant is shown in figure 1. The process equipment utilized in the "low productions are described as follows: TILT HOIST/SIZER The input rough lumber is unloaded onto the spreader conveyor using a Forminor tilt hoist, manufactured by a local mech'se shop. The lumber is then conveyed and fed into a Stetson Ross planer, rated at approximately 250 to 350 lineal feet per minute. Material is sized on one side and one face to within 1/8 inch for both thickness and width. The lumber face containing the most defects is sized in order to make defect identification and trimming easier. Material deemed unacceptable for fingerjointing is discarded at this station. Operating functions are regulated via a console-mounted control. DEFECT TRIM SAWS Sized material is conveyed to foot-controlled trim saws (3) manufactured by Precision Products Company, Model 28RH. Materiel suitable for finger­ jointing is conveyed onto the shaper table while defective material is discarded. DUAL FINGERJOINT SHAPER The fingerjoint shaper is a dual unit with left and right hand shapers, having a common bed, two feed chains, anc an automatic transfer system. The machine is manufactured by Industrial Woodworking Co., Model 11-3496R. The feeding lugs are positioned on 18 inch centres and feed speed 3 is variable up to 40 1ugs/minute. e lug carries the material under pneumatic hoi down pressure past the first precision trim sa.w and cutter- head. The first cutterhead is on the left side of the shaper table, as viewed from the infeed end. The material is tnen transferred across the table by a powered cross-over belt and carried past the second trim saw and cutterhead. The trim saws are equipped with fine horizontal adjustments to control finger length. The cutterheads are equipped with fine adjust­ ments for raising or lowering the units to ensure good finger match. The knife blades for the cutterheads are manufactured by Badger Co., (Wisconsin Knife Works, Model BG 824 BAL F). The fingerjoint produced is a horizontal type with a desired finger length of 0.987 inch, finger base of 0.209 inch, and a finger tip width of 0.030 inch, illustrated as follows: FINGERJOINT PROFILE ! 4 After the material is profiled on both ends, the material is removed from the shaper table by pick-off fingers and manually stacked according to length prior to pre-heating. H ■ AIR OVEN The hot air fingerjoint pre-heat oven is manufactured by Lockhead Haggerty Engineering Manufacturing Co. Ltd. The interior dimensions of the oven are 36' length, 8' 3" width, and 16" r. • cht. Lumber travels through the oven in parallel piles on a cha n conveyor powered by a variable speed motor. The speed of the feed is regulated to produce a finger temperature of 194°F to 203°F (S0-95°C) at the oven output. The residence time of the lumber in the oven is dependent upon the initial temperature and moisture content, but will usually be between 5 and 30 minutes. Initial start-up of the oven burner is accomplished using natural gas. Steady-state operation is achieved using oil and wood wastes. The forced hot air is blown directly at the ends of the lumber in the oven and then recirculated through a heat exchanger. The temperature of the input air is automatically modulated between 320 and 347 °F (160 and 175°C) by means of a controller and a thermocouple located on the inlet air duct of the oven. Dial-guage thermometers placed on each side of the oven are also used to monitor air temperature in the vicinity of the moving lumber. GLUE APPLICATOR Boards leaving the oven are transferred onto the glue applicator conveyor (Industrial Woodworking, Model GAC-8), ihe glue applicator conveyor has lugged chains and carries the dumber under pressure past an aligning device and the glue applicator. For glue application, an APQUIP glue sprayer is utilized. This equipment automatically sprays glue to one heated end of the lumber. It is also equipped with a foot-switch for manual spraying to prevent nozzle clogging during stoppages. ASSEMBLY MACHINE After glue spraying, the lumber is conveyed to an automatic assembly feeder (Industrial Woodworking Co., Model ASF-28) which permits a constant linear flow of material to the assembly machine. The lumber is fed linearly into the infeed section of the assembly machine (Industrial Woodworking Co., Model 9HP-28-24R) in a continuous ribbon. Feed speed is variable from 75 to 175 feet per minute. The lumber pieces are butted end to end and passed through side aligning rolls and through the 4 main polyurethane covered, power-driven feed rolls (crowder rolls). The first set of rolls drive while the last set provide resistance, resulting in " squeeze-up" pressure. The pressure developed in the lumber between the rolls causes a slippage which is absorbed and controlled by air loaded constant slip clutches. A maximum joint force of about 7,500 pounds can be produced between the crowder rolls. After the crowder rolls, the fingerjoined lumber is fed across 20 feet of crossover slide with hoi down bars. Heavy duty rubber holdback wheels are positioned following the crossover slide. These wheels prevent spring- back of the joints. 6 FLYING CUT OFF SAW The flying cut off saw (Industrial Woodworking Co.) trims the continuous ribbon into desired lengths of up to 24 feet at rates from 75 to 175 lineal feet per minute. The cut off saw is directly linked with a length limiting actuator. DISCHARGE UNIT The discharge . it is manufactured by Industrial Woodworking Co. The unit is approx. Lely 24 feet long and has 12 discharge chains which transfer the material to the curing table. CURING TABLE After cutting, the lumber is discharge onto a 37 foot long curing table.