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Cross-Laminated Timber (CLT)
Cross-Laminated Timber (CLT)
BRIEF HISTORY
Although a relatively recent development, cross laminate timber (aka Cross-lam or CLT)
has its origins in the traditional timber technologies of central Europe and Scandinavia. The
evolution of the concept of a composite with rigidly bonded crosswise layers from research
through to a fully realised construction product happened during the 1990s. Early engineering
research occurred first in Switzerland and then in Austria. Meanwhile in Bavaria, the first 3 storey
house was erected by the German timber company Merk, where then the composite was known
by the Germans as ‘Dickholz’ – translated as ‘thick wood’. There followed for a period of 5-6
years during which time the composite was experimented with by small timber manufacturers in
the sub-Alpine regions of Germany, Austria and Switzerland. In the early 2000s, manufacturing
and construction techniques had matured enough for full-scale production to begin. As the
popularity of the ‘new’ timber technology spread, other European countries started-up their own
manufacturing capacity.
Meanwhile in the UK, construction had barely evolved beyond traditional masonry
technology. Timber frame had been making some in-roads, but couldn’t escape its association
with fire. The engine room of the construction industry, the house builders, were and still
operate within the strictures of the insurance companies nervous of innovation as well as a
consumer audience locked into historicist fantasy. The builders’ mantra continues to be ‘If it
works, don’t fix it’.
The more inspired design-led and less tremulous public sector, private clients and their
architects tend to be more open-minded. It was into this culture that a few adventurous
practices introduced cross-lam during the early years of the ‘noughties’.
In addition to the usual sense of adventure, architects adopting cross-lam/CLT during this time
were driven by a number of coincidental factors:
- the turning screw of Part L demanding improved U values
- a growing awareness of the environmental impact of materials
- the then Labour government’s Building Schools for the Future programme.
MANUFACTURING PROCESS
1. Species selection
The main species currently used for CLT is spruce. Though Scots pine, larch and
Douglas fir are also available. Swiss stone pine (Pinus sylvestris) can be used in in an
outer layer to provide a high quality finish to exposed panels.
2. Drying
Planed boards of between 12 and 45 mm thickness kiln-dried and conditioned
down to a moisture content (MC) of 12% +/- 2%
3. Strength grading
Boards are graded in the range C16 to C24. C24 use is still more common,
though C16 timber is more readily available in the UK – suggesting that CLT
manufacturing might become more feasible in the future.
4. Visual grading
Surface quality is defined by BS-EN 13017-1 Solid wood panels. Classification by
surface appearance.
There are three different grades:
Residential Visible – planed and sanded
Industrial Visible - planed and lightly sanded
Non-Visible – planed
5. Removing defects
According to the strength and final visual quality, defects such as large knots and
resin or bark pockets are cut out.
6. ‘Endless’ lamellae
Individual boards can be joined to make, in principle, an endless lamella (layer)
using finger joints to marry the boards. The lamellas are then planed to a uniform
thickness. (Layer assembly: Some manufactures assemble individual layers or plates at
this point – ahead of forming the panel. Layers are assembled by bonding along the
edges of each lamella up to the desired dimensions. Panels are then built-up from these
individual layers)
7. Panel assembly
Panel sizes vary by manufacturer and application, CLT panels can be
manufactured in 3, 5, 7 or more board layers with typical widths of 0.5m, 1.2m, and 3m
and lengths of up to 18m long. Transport by lorry is the ultimate limiting factor and in
the UK restricts practical lengths to 13.5 m. Generally panels are manufactured up to
300mm in thickness, but larger dimensions are not unknown.
The outer layers of the panels are usually orientated to run parallel to the span
direction. That is, for walls that are normally oriented, the outer layers of the CLT panels
have the grain direction parallel to vertical loads to maximise resistance. Likewise, for
floor and roof CLT panels the exterior layers run parallel with span direction.
The lamella strips are spread with adhesive and then adhered perpendicularly to
the lamellas of the adjacent layer. Effective adherence is ensured through using either
vacuum or hydraulic press techniques. The completed CLT panel is trimmed along the
edges.
8. Completion
The completed assembly is then planed and/or sanded before transfer to a
machining station where a multi- out openings for windows and doors in walls and
staircase openings in floors.
Adhesives
Surface-bonding adhesive is usually applied mechanically and without contact either on
(i) single lamellas in a continuous through-feed device or (ii) on complete CLT layers already
positioned in a positioning or press bed.
A range of glues have been used historically to bond engineered timber. The biggest
initial development was that of waterproof phenol-resorcinol-formaldehyde (PRF ) resins in the
1940s. This allowed engineered timber to be used in external environments without threat of
degradation.
In the 1970s melamine-urea-formaldehyde (MUF) was introduced which improved on
the PRF resins but became known to form rather brittle bond lines.
1994 saw the introduction by Purbond AG of the first commercially
successful PUR (one-component polyurethane) adhesives. Since then other manufacturers have
produced other PUR types enough to dominate the adhesive market.
The development of PUR was important because of a number of significant advantages
over previous adhesives:
• One component – no mixing and easy handling
• No off-gassing of volatile organic compounds (VOCs) including Formaldehyde
• Solid content without solvents
• Reduced processing time resulting from fast bonding and reduced press time
PERFORMANCE CHARACTERISTICS
Insulation performance
Thermal conductivity (λ lambanda value) : 0.13 W/mK (spruce). CLT insulation
performance is similar to aircrete blockwork and better than concrete blockwork or brickwork.
Additional insulation is usually required (see External cladding) to upgrade the element to a
higher performance. Passivhaus standards are easily achievable.
Airtightness
Crosslam / CLT construction generally has a reputation for being able to achieve high
degrees of airtightness through the timber technology alone – rather than, say, with the addition
of a vapour control layer.
Good airtightness is achieved through well-matched contact surfaces screwed together.
In addition, its common to find additional sealing at junctions such as those of the floor / wall
and wall / pitched roof types. Additional sealing can be achieved through using pre-compressed
foam tape or breather tape or sheets of airtight material.
However, because of shrinking cracks near the edges of the panels and movements in
the panels caused by shrinking and swelling, there is a risk that local sealing might break down
and fail over time. If this risk is considered significant, it might well be that the designer includes
a vapour control layer or vapour permeable ‘intelligent’ membrane (used with other vapour
permeable cladding materials) over the external face of the panel to ensure long-term
airtightness.
Moisture protection
Cross laminated timber is a vapour permeable and vapour retardant construction
material. The vapor diffusion resistance value is between μ = 40-80, dependent on the moisture
content.
Where vapour-permeable (‘breathing’) external cladding materials, such as cellulose, woodfibre,
hemp etc., are used, a vapour control layer is not needed.
Acoustics
Though the acoustic performance of CLT is good and stands well in comparison with
other materials, relying on floor or wall panels alone to provide required levels of sound
reduction is difficult. In addition to direct sound transmission reduction, care needs to be taken
in ensuring that flanking sound is also addressed. Typical flanking paths include continuous CLT
subflooring, leaks around the edges of partitions, joints between floors and surrounding walls
and leaks through electrical outlets.
Floors and ceilings
The use of an air gap is the most effective measure in improving performance and can
be located above or below the CLT floor.
A below the ceiling solution might typically be a double layer of plasterboard suspended
below the CLT floor on resilient supports and rails along with sound absorbing insulation in the
air gap,
Above the floor the standard European solution is a concrete floor screed laid over a
sound absorption layer and rigid insulation. However other options would include combining
the suspended ceiling with a floating floor or timber laminate flooring laid over a sound-
absorbing underlay.
Compartment walls
Sound reduction can usually be found by either sandwiching one CLT panel between
layers of natural fibre insulation and plasterboard OR by using two CLT panels separated by a
gap containing sound absorbing material and plasterboard to external faces.
FIRE RESISTANCE
One of the major advantages of Cross Laminated Timber is its inherent fire resistance.
CLT can be designed to accommodate substantial fire resistance and unlike steel remains
structurally stable when subjected to high temperatures. CLT panels can be produced with fire
resistances of 30, 60 and 90 minutes.
It’s easy to see why any form of timber construction can pick-up a reputation for fire risk,
but for solid wood and Cross Laminated Timber, performance in a fire is a long way from their
timber frame cousins.
To understand how efficient CLT is in a fire, we should start with the understanding that
fire resistance is the ability of a material to confine a fire or to continue to provide a structural
function or both.
The measure of fire resistance is the time elapsed from the start of the fire up until the
point where the material fails to function. Typically resistance is expressed in minutes eg FR 30,
45, 60 or 120.
CLT’s fire resistance is provided through ‘charring’. As soon as the face of the timber
panel is exposed to a fire that ramps up to a temperature in excess of 400 degrees C, the surface
of the timber ignites and burns at a steady rate. As the timber burns it loses its strength and
becomes a black layer of ‘char’. The char becomes an insulating layer preventing an excessive
rise in temperature within the unburnt core of the panel. It is this unaffected core which
continues to function for the period of the fire resistance.
To achieve the designed fire resistance period there must be sufficient virgin solid timber
remaining behind the char layer to sustain the loads applied. Therefore each CLT panel within
the building must be designed for the fire resistance period and the specific loadings applied to
that panel.
Fire resistance testing of CLT panels is to ISO 834 – the same standard used for door sets
which most of us are familiar with.
HISTORY
CLT was developed in Austria in 1996, and Europe remains the leading region for
its production and use. There are fewer CLT manufacturers in North America, but
its incorporation into US code and, therefore, building structures is growing –
though codes have been restrictive towards the product’s use in buildings of six
stories or more, this is changing.
A new generation of engineered wood product developed initially in Europe, has
been gaining popularity in residential and non-residential applications in several
countries.
CLT is an innovative wood product that was introduced in the early 1990s in
Austria and Germany and has been gaining popularity in residential and non-
residential applications in Europe.
In 2015, the International Building Code (IBC) began recognizing CLT products
manufactured to ANSI/APA PRG-320, the US standard for Performance Rated
Cross Laminated Timber. Efforts are afoot that may lead to more product
acceptance over the next few years. For example, The International Code Council
(the body that establishes the IBC) appointed an Ad Hoc committee to focus on
Tall Wood Buildings and have proposed 19 code changes for the 2021 edition,
allowing the use of wood in buildings across a much broader spectrum, including
those up to 18 stories. In December of 2018, The International Code Council
(ICC) has released the unofficial voting results on the proposed code changes,
including passage of the entire package of 14 tall mass timber code change
proposals. The proposals create three new types of construction (Types IV-A, IV-
B and IV-C), which set fire safety requirements, and allowable heights, areas and
number of stories for tall mass timber buildings. Official results are expected to
be announced during the first quarter of 2019. The new provisions will be
included in the 2021 International Building Code (IBC).
ADVANTAGES
o The cross-laminating process provides improved dimensional stability to the
product which allows for prefabrication of wide and long floor slabs and single
story long walls.
o Additionally, cross-laminating provides relatively high in-plane and out-of-plane
strength and stiffness properties in both directions, giving these panels a two-
way action capability similar to a reinforced concrete slab. The ‘reinforcement’
effect provided by the cross lamination in CLT also considerably increases the
splitting resistance of CLT for certain types of connection systems.
o CLT wall panels can be used as an effective lateral load resisting system
o Sustainable
o Easier onsite delivery
o Faster installation
o A cleaner, drier construction site
o No specialised construction experience needed
o Less expensive foundation (due to lighter weight)
o Reduced waste
o Fire-resistant wood construction
o Better thermal properties
o Reduces onsite labor by up to 50%
o Increases project schedule by up to 25%
o Performing close to Passivhaus standards requiring minimal heating
o CLT creates long term storage for CO2 sequestered during tree growth
DISADVANTAGES
o CLT is more expensive than steel or concrete
o Code restrictions on timber building heights
o Costs of electrical, plumbing and other services can increase (no wall cavities)
o There can be higher architectural/design costs
o A higher material transportation cost (relatively few manufacturing plants)
o Less long-term flexibility (think future renovations)
CLT’s cost for materials and labor may be lower than traditional steel or concrete. Though
variable, material cost savings may be as much as 15% compared to concrete, steel, and
masonry for mid-rise residential buildings. Why? CLT is lighter, so requires a smaller foundation.
Labor demands for CLT projects are also less. In a tight labor market, this can be significant.
Prefabricated panels require fewer workers to place them. There may also be options around
which type of labor is used.
Have a CLT project in your pipeline? While it’s trending in the construction market, it is
important to invest the time to look beyond the benefits to understand the issues. For all the
advantages discussed in Part 1 of this series (Part 1: The benefits and risks of building with
Cross Laminated Timber), few come without a caveat. The risks associated with using CLT are
similar to those of other prefabricated components, versus the usual wood frame risks. They
can be managed, but it requires up front attention and ongoing diligence. Here we discuss
some of the common concerns cited along with strategies to manage them.
Coordination and process
CLT construction requires full, detailed modelling (BIM) and coordination - up front. Product
manufacturers drive this level of planning by necessity. They know the questions to ask and
won’t fabricate until the details are clear. This puts pressure on owners, designers, engineers,
and architects to think the project through and get it right.
The planning phase is key
The advanced use of modern planning and design technology tools is, itself, a potential risk
mitigation strategy. With all that goes into producing prefabricated components like CLT, the
likelihood is much greater to “build it once”. There is little opportunity for “value engineering”
or late modifications. Because of this, Builders and their subcontractors are required to be
more intensely involved in the planning phase, which requires more sophistication than the
traditional work flow. If they are not up to the task, the burden of making the project buildable
falls on engineers and architects, and this is not optimal. A better result will be realized when
all the parties who will actually build the structure are involved in the earliest possible details.
Subcontractor selection
Choosing the right subcontractors for a CLT job could not be more important, but it’s
challenging when the building material is new to the marketplace. How do you navigate:
1. Subcontractor Selection. Who has the ability to install the product? In most geographies,
subs will have little or no experience with CLT. Should you use outside resources or your own
internal forces? If using outside resources, which trades will you turn to for bids? In Union
spaces, wood construction of any type means carpenters do the work. If the project also
contains a lot of glue laminated timber (GluLam), that may mean a timber framer. In non-
union environments, resources may also include tilt-up or steel erectors. Your CLT
manufacturer may also have resources for your consideration.
2. Pricing. The subs on your bid list may never have even heard of CLT, and may bid higher
than is necessary because they are unsure. When the initial response to the process when
described is “it can’t be that simple”, pricing tends to reflect a fear of the unknown “gotcha” –
although CLT generally is simple to put in place.
3. Subcontractor prequalification. Because your subs have less (or no) experience with the
product, you will have limited ability to vet subs based on similar projects as you typically
would. In this situation, your prequalification process becomes even more important and also
more challenging. Pay attention to everything the process tells you, and act on it with
appropriate risk mitigation to addresses operational and financial risks.
Many Builders approach CLT installation using their own forces first. Internal performance may
be desirable for several reasons. It advances the builder’s knowledge and experience for future
projects. In short, it is an opportunity to really learn the product. It also leads to increased
schedule control and provides the ability to adjust course as needed.
One builder experienced significant production delays on materials due to slow owner design
decisions. If they had used outside labor, this might have been a disaster as the selected sub
rolled on to their scheduled work for others – but the builder’s internal forces stood ready,
following subcontractors were directed to prefabricate components/assemblies where it made
sense, and they made up significant time, which shows some of the value of this approach.
Transportation risks
Transportation issues can be more than just an inconvenience; they can have large physical
impacts too. Transportation considerations with CLT are similar to those of precast concrete.
Different manufacturers can make different size panels and designers may be dazzled by the
possibilities. But state to state or international permits and limitations on transport according
to all authorities having jurisdiction require serious consideration prior to finalization of the
design.
Consider the case of Wake Technical Community College Pedestrian Bridges in Raleigh, NC.
The project included long Glulam girders and trusses (not CLT, but the issues are similar) as a
major component. Over-the-road transportation size restrictions resulted in retrofit
connection details–connections which ultimately failed and led to two bridge collapses, one of
which resulted in a fatality. This catastrophe was directly related to a failure to consider all the
issues surrounding getting the designed materials to the site. Had the size restrictions on
transportation of the material been fully understood at the design phase, different decisions
may have led to a better outcome.
QA/QC - Manufacturing and on-site concerns
Use of CLT should mean more manageable QA/QC. However, while site based activities are
simplified, the means and methods may be completely new to your crews. And although there
are standards for CLT’s manufacture, they must be understood and followed. Any
manufacturing issue has the potential to be a large structural or repetitive defect.
Manufacturing QA/QC - Because of controlled conditions at a manufacturing facility vs. the
more fluid conditions on a project site, quality can be expected to be higher on a CLT project.
USA produced materials are intended to adhere to CLT ANSI APA PRG 320 third party
certification. Since the cost of entry into this market is very high, those involved, especially
newer manufacturers, are committed to getting it right. However, they may not have the
experience or knowledge to do that. For example:
The future home of OSU School of Forestry used a supplier who had recently obtained the
equipment to fabricate CLT, but had no previous experience with a CLT project of this size and
complexity. The company was specified by the Owner, leaving the Builder little choice in the
matter. After installation, a 20x4ft, 1,000-pound section of the third floor buckled and crashed
onto the floor below. Engineers traced the panel’s failure to the glue and initially found at
least five other panels which showed signs of delamination. Upon checking all panels, it was
determined that at least 85 panels should be replaced.
An internal audit of the manufacturing process revealed that crews had been instructed “to
warm the lumber in stacks under tarps,” prior to gluing them to make the panels. “Some
temperature variations inadvertently caused premature curing of the adhesive, resulting in
poor bonding,” the company said. No doubt this was not what they intended, but the
manufacturer did not have the experience to know that this technique might fail.
If you are considering CLT, take your time, think it through, and do your diligence
before diving in. The stakes are high.
Production standards - A product standard is a great first step towards ensuring that the
materials will be produced to specification. Your manufacturer has to make that happen, but
how are they managing it? Visit the manufacturing facility to get comfortable with them, and
engage in a thorough prequalification process to understand their operation, internal QA/QC,
reputation, etc.
Imported CLT materials may seem like more of a wild card, however, in this case, European
manufacturers abide by the standard EN 16351 and may have the benefit of more experience
with the product. Do your due diligence to make sure your manufacturer, wherever they
reside, is up to the task. Understand the standards and processes, and focus on issues
surrounding your supply chain.
Site QA/QC - Expected improvements in building quality are related to using prefabricated
components, meaning tighter tolerances and fewer pieces/materials/transitions in the field.
This should translate into easier to manage QA/QC on site and higher performing buildings.
Because of the novelty of CLT projects in North America, Builders likely won’t have a
superintendent on site who has been on dozens of similar jobs and can just tell when
something isn’t right. On a straightforward CLT project, this may not have a serious impact.
However, on a boutique type project, which many CLT projects are, this becomes tougher as
teams don’t have the usual baseline knowledge to build on.
A manufacturers’ consultant may be available to help bridge that experience gap, for a cost.
Consider whether it is worth the expense your first time out, especially if the project includes
complex or specialty details.
It is also critical that all team members understand the process for onsite modifications. CLT is
a system, and all onsite mods/penetrations should go through your Request For Information
(RFI) process to maintain the integrity of that system. The temptation can be there to cut it,
since it is wood and easy to cut. On the other hand, since it is often a visual component which
will not be covered, subs may be less likely to make unauthorized modifications, knowing they
will remain visible. In any case, make sure the procedure for modifications is clear and
followed.
Do your diligence when considering CLTWe are likely to see more CLT use in building
projects in the North American market. As demonstrated in this series, there are a host of
considerations to weigh when thinking about undertaking a CLT project. If you are
considering CLT, take your time, think it through, and do your diligence before diving in. The
stakes are high.
Moisture and weather are the most important enemies of wood. Exposed timber suffers, and
since CLT is a structural component, we have to protect it to avoid its wear, corrosion, and
collapse. While it's possible to add supplementary layers of coating to wood, such as fiber
cement, brick, stone, or other materials, there are also ways to preserve exposed CLT.
Vegetable oils and mineral paints can meet these objectives if applied only once every 5 years,
guaranteeing 25 years of protection without detachment or discoloration.
Vegetable oils are recommended for indoor use, while mineral paints work best outdoors, mainly
on walls. These products, which are odorless and high performance, can be applied by anyone,
following basic instructions and taking necessary precautions.
During its manufacture, CLT must be made with structural wood –knowing the structural grade
of each board– since the quality of the panel will be the result of the quality of the wood used.
In addition, it's necessary to consider that the high precision of CLT must be able to be
combined with the foundations that will receive it, avoiding, for example, concrete slabs that
present imperfections. Even millimetric variations could generate huge headaches during
installation.
CLT panels are currently allowing the construction of buildings with up to 30 floors, in Canada,
and up to 40 floors in Finland. The future is promising and we will remain attentive to your
progress. Perhaps in some years, our cities will be transformed based on the warmth and texture
of the wood, also changing the way in which the design and construction of our works are
conceived.
When a project is started in CLT, everything is completely decided and predetermined at the
factory, and it's not possible to make adjustments on site. So, more than builders, the people
who work with CLT are assemblers, who must articulate virtually perfect pieces. CLT behaves
with the precision of a piece of furniture, working with margins of error of 2 millimeters.
While the project stage can take a little longer, the assembly is of an amazing speed: in the case of
a house of 200 m2, the assembly can take 5 days and occupy a minimum workforce (around 4
instructed people).
Regarding the regulations, there are regulations in the world that guide the design and
construction with CLT, but they are the sum of different aspects present in the Standards
commonly used in concrete and laminated timber. In 2017, the standard currently used in the
United States was published, which is simply a summary of European Standards.