CROSS-LAMINATED STRUCTURAL TIMBER PANELS D ES I G N , …

C R O S S - L A M I N AT E D S T R U C T U R A L T I M B E R PA N E L S

D E S I G N , M A N U F A C T U R E , S U P P LY & E R E C T I O N

Conferences Cecobois et Salon Solution en Bois Montreal

21st February 2014

INTRODUCTION

Kay Hartmann – Head of Design KLHUK

INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

T H E W O R L D ’ S TA L L E S T R E S I D E N T I A L C LT S T R U C T U R E

M E L B O U R N E / A U S T R A L I A

FORTE


• KLH UK • BUILDING WITH CROSS LAMINATED TIMBER • PROJECT BRIEF • DESIGN PROCESS • MANUFACTURE • LOGISTCS • SITE • CLOSE

T H E W O R L D ’ S T A L L E S T R E S I D E N T I A L C L T S T R U C T U R E

FORTE

• KLH – founded in 1997 • is one of Europe’s largest

suppliers of cross-laminated structural timber panels

• 15 European sales partners, 1 subsidiary.

• 5 International Markets. • Factory capacity

exceeding 900,000m2 • Carbon neutral

production


• World leading expertise in cross-laminated timber construction – from design concept to on-site completion.

• Collaborative working approach – developing sustainable and cost effective structural solutions by working with the clients team from the earliest stages of the design process

• Innovative and ground breaking project experience across the education, commercial, health, public & civic and residential sectors

KLHUK

INTRODUCTION I KLHUK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

• Timber is the only renewable structural building material

• Timber has the lowest energy consumption of any building material across its lifecycle

• Using solid timber will reduce CO2 emissions when used in place of ‘traditional’ construction materials i.e. concrete, steel, brick & block etc.

BUILDING WITH (CROSS LAMINATED ) TIMBER


CO2 Absorbed

CO2 Omitted

2,000kg

1,000kg

1,000kg

2,000kg

Cement

Steel

Cross-laminated Timber

870kg

1,700kg

800kg

1,500kg

500kg

1,500kg

500kg

Sequestered Carbon – 250kg





KLH = KreuzLagenHolz Engl. = Cross Laminated Timber


Pressure 6kg/cm2 = 60t/m2

(2,900 tonnes per panel)

2.95m

16.5m

Maximum width/height

Maximum length

57 - 320mm

13.5m due to transportation


Panels for floors ceilings etc.: TL

(Top layers Longitudinal)

Panels for walls: TT

(Top layers Transversal)


The (R)evolution of Timber Structures


WHY (TALL) TIMBER BUILDINGS?

• by 2050 three billion more people - 30% increase over Earth's current population.

• 70% of the population will live in cities

• efficient use of resources critical

• wood captures CO2

• with more and more people needing houses moving to cities, is there a sustainable alternative to building with timber?


PROJECT BRIEF


• 10 storey residential tower

• 9 storeys CLT

• Height 32.17m

• RC podium slab

• 23 apartments + retail

KLHUK + KLH M provided

• Architectural Design + Engineering Consultancy Services

• CLT design coordination and fabrication drawings

• CLT supply

• Transport logistics

• Installation advice

• Site operatives training

DESIGN PROCESS/SCOPE


DESIGN PROCESS



PLATFORM SYSTEM

Forte is a cellular structure …



…with the apartments in a honeycomb pattern…


…arranged around the central core…


…and stair wells. …


The structure with its orthogonal walls and floors…


…forms a three dimensional system of interlocking plates…


…that has been exploited to maximise …


…the robustness of the structure…





ANALYTICAL MODEL and LOADING


DESIGN ANALYSIS:

• DLUBAL finite element software

• KLH design software

• KLHUK calculation spreadsheets

• Hand calculations



DESIGN

ANALYSIS:

• Wind loads



DESIGN

ANALYSIS:

• vertical

deflection

DIMENSIONING of ELEMENTS


Member Design

• Floor + Roof: – 145mm 5 layer KLH TL panels

• Stair waist :

– 145mm 5 layer KLH TL panels

• Walls: – 128mm 5 layer KLH TT panels

for REI 60

– 158mm 5 layer KLH TT panels for REI 90

KLH wall panel

Steel angle bracket

Shim

DPC layer

Concrete slab

• Typical RC Slab Interface Detail

End-grain sealer

CONNECTION DESIGN


KLH wall panel

Steel angle bracket

Air tightness tape

KLH wall panel

KLH floor slab

KLH wall panel

CONNECTION DESIGN • Typical CLT/CLT Interface

End-grain sealer


CONNECTION DESIGN • Typical Connection Details – corner and half lap


CONNECTION DESIGN • Typical Connection Details – lift shaft and floor joint


CONNECTION DESIGN • Typical Connection Details – balustrade and wall/floor


• Combustibility is dependent on the surface/volume ratio

– you don’t start a fire with logs!

• No damaging thermal expansion

• Loss of load bearing capacity is a result of reduced cross-section only.

• Timber is highly predictable when exposed to fully developed fire conditions

FIRE PERFORMANCE - KLH INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

Pre-ignition Fully developed Burning Decay

Ignition Flashover Time

Tem

per

atu

re

Behaviour of timber in fire:

Approx. 300oC for piloted ignition

The fire protection of the structural elements of the timber superstructure is typically provided by the covering finishes

Exposing CLT

Where structural elements are exposed, the CLT panels have been designed to provide the required fire resistance by charring I.e. additional sacrificial timber material has been included for.

The fire design was carried out in accordance with Eurocode 5 (EN 1995-1-2 ) and KLH's ETA (European Technical Approval) -06/0138

For Forte all exposed CLT panels provide a fire resistance period of 60minutes for single sided exposure

FIRE PERFORMANCE - FORTE INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

• Timber buildings must satisfy UK Building Regulation Part A3

Disproportionate Collapse • Eurocode 1-7 provides a strategy for limiting the extent of localised failure which should

provide a building with an acceptable level of robustness

• Principles of this strategy are:

– Effective horizontal and vertical tying of the structure and

– Notional removal of load bearing elements e.g. redundancy and alternative load paths.

Where the notional removal of elements results in an extent of damage in excess of the agreed limit then such elements should be designed as a ‘key element’

• Key elements designed to sustain notional accidental action Ad ( 34kN/m2 )

ROBUSTNESS INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

• Creep movement (dependent on moisture content)

– Walls ~negligible < 15 storeys

– Floors ~1.2mm typical

(perpendicular to grain

long term E-300 N/mm2) ~0mm

~1.2mm max.

MOVEMENT INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

• Moisture movement assuming 6% mc change (14% - 8%) – Wall panels

(parallel to grain

0.01% per 1% of MC change)

– Floor slabs

(perpendicular to grain

0.2% per 1% of MC change)

~1.8mm

~2.95m

~145mm

~1.8mm

MOVEMENT


• Thermal movement contrary to the moisture movement

– Walls ~negligible

– Floors ~negligible ~0mm

~0mm

MOVEMENT

INTRODUCTION I KLH UK I BUILDING WITH TIMBER I PRODUCTION I CROSS-LAMINATED TIMBER I TECHNICAL I PROJECTS I CLOSE

• Combined 4.8mm max per floor

• Detailing to accommodate movement

~4.8mm

~ 43.2mm

1

2

3

4

5

6

7

8

MOVEMENT


9

STRENGTH

For FORTE we developed a special bearing detail that introduced hardwood cylinders providing bearing reinforcement at the lowest two timber slab levels.

Reducing the compression onto the slab and offering a more direct vertical load path


• Acoustics

• Airtightness

• Thermal Mass

• Thermal insulation

BUILDING PHYSICS


• The KLH panels are approved to be used in

Service Class 1 or 2 according to Eurocode 5

• Maximum permitted Moisture content – Service Class 1: 14%

– Service Class 2: 18%

• Accelerated life cycle tests are

carried out in the factory

• The KLH system has a certified

Design life of 60 years (ETA)

DURABILITY


MANUFACTURE INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

• Timber boards are kiln dried to 12% +/- 2 • High pressure bonding system with solvent-

free and formaldehyde-free adhesive (‘0’ emission class)

• Panels are manufactured, designed and processed using CAD/CAM technology and state-of-the-art CNC panel cutting machines

• ‘Rolling process’ through factory – ultimately delivered on a just-in-time basis

MANUFACTURE


MADE FOR BUILDING – BUILT FOR LIVING

• Low-tech, low energy and zero waste manufacturing process

• All off-cuts, wood shavings and sawdust are manufactured into biomass pellets used to generate heat / power for the factory (excess is sold to local CHP plant)

• KLH panels are manufactured from wood from certified timber sources and sustainably managed forests (PEFC or FSC available)

MANUFACTURE INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

LOGISTICS INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

• Testing

• Import Logistics

• Programme

• Communication

• Fabrication drawings and approval

• Panel and fixings order

• Quality Assurance during manufacture

• Shipment

FABRICATION DRAWINGS INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

ERECTION SEQUENCE INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

QUALITY INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

• Development of project specific Quality Assessment Guideline

• rigorous quality control

QUALITY CHECK INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

SHIPMENT INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

SHIPMENT INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

SITE


• Site manager training in UK

• RA/MS

• Site drawings

• Temporary works

FORTE MELBOURNE • Design: LendLease • Main Contractor: LendLease • Project Details: Value: $11m Dates: 2011 – 2012 Services: Architectural Design + Engineering

Consultancy Services

CLT design coordination and fabrication drawings

CLT supply

Transport logistics/Installation advice

Site operatives training Timber volume: 1,052m3

Build period: 12 weeks

• At the time of construction Forte was the tallest cross-laminated timber apartment building in the world

TEMPORARY WORKS


Plugs for lifting holes

Hardwood bearing reinforcement

Forte Melbourne June 2012



Forte Melbourne August 2012

Forte Melbourne September 2012

CARBON CALCULATION • KLH cross-laminated timber volume –

1,052m3

• KLH panels: removed approx. 841.6 tonnes

of CO2 from the atmosphere • Total stored/sequestered carbon in KLH

panels for the residential development – 252.5 tonnes

Thank you

Visit our

website at

www.klhuk.com

or

contact

www.klh.at

FOR MORE INFORMATION INTRODUCTION I KLH UK I BUILDING WITH CLT I PROJECT BRIEF I DESIGN PROCESS I MANUFACTURE I LOGISTICS I SITE I CLOSE

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