We began raising the first complete Cross Laminated Timber (CLT) building in New York State on our main campus in Farmington, NY in late January 2017. A combination of mass timber, heavy timber, and CLTs, the 21,000 sq ft building will house our fine woodworking division, NEWwoodworks, and offer a bit of storage/shipping for our sister company, Pioneer Millworks. CLT construction is an economically and environmentally conscious alternative to steel and concrete construction, a material that is new to the U.S. building industry.
From site prep to flying the the final CLT panel:
What are CLTs? A quick description might be ‘giant plywood’. More specifically, CLTs are large wooden panels, typically consisting of 3, 5, or 7 layers of dimensional lumber, oriented at right angles, glued together. The panels for our project averaged 8 feet tall and 38 feet long at 3 ¼ and 3 ¾ inch thickness. Using a crane and lulls, the panels were lifted into place and fitted by hand to the supporting timber frame. Each CLT panel has a shiplap edge that nests the panels together and is secured with metal fasteners.
We see CLTs as a wave of the future and we’re investing in our Western New York campus to better position the region and our industry to ride the wave. The opportunities with CLTs are abundant for businesses and housing and offer dramatic environmental benefits. Wood is a naturally occurring and renewable resource which stores carbon. It has proved time and again to preform as well, and at times better than, carbon heavy steel and concrete.
The CLT panels are pre-designed, highly engineered, of superior quality with precise tolerances – all specific processes and requirements that are fundamental to our timber framing craft. This fits perfectly with our traditional work and parallels the SIPs integration that we’ve spearheaded for years. The project combines the strength of mass (glulam) timbers and heavy timbers with CLT panels, utilizing a timber frame wrapped by CLT walls and topped by CLT roof panels. The panels arrived from Austria, shipped by sea (which had about half the carbon impact in comparison to shipping by land across the US or from Canada) with pre-cut openings for windows and doors. These panels were made using smaller Spruce trees from sustainably managed forests in the EU.
Raising the frame and installing the panels (walls and roof) for this project took just under three weeks. This is our first CLT project and we now know first-hand that time on site is minimized and there is little waste with this product. While there was a learning curve, the process was amazingly smooth. Many accolades for our co-workers who are dynamic thinkers, unstoppable doers, and all around great people. Darren, Mike, Noah, Michael, Quinn, Todd, Anthony, Kevin, Marc, Mike G, and Wes to name a few who spent hours on the ground – also on ladders, in lulls, and on the roof – in chilly, wet, sunny, and snowy conditions.
A little dancing was in order as the last panel was installed (see Todd on the far left):
We’re excited to have our fine woodworking division on our main campus. In February of 2015, NEWwoodworks, located in neighboring Shortsville, NY, suffered a catastrophic event as excessive snow loads caused half of the roof collapse over their 70-year-old building (no one was injured). NEWwoodworks will be entrusted with 13,000 sq ft of the new CLT building while Pioneer Millworks will utilize 8,000 sq ft for reclaimed wood storage and shipping. We’ve expanded our Farmington office space to accommodate the NEWwoodworks design and management team, as well as give Pioneer Millworks a bit more elbow room.
We anticipate easier communication and workflow allowing us to better serve our clients by joining NEWwoodworks with our main campus and giving Pioneer Millworks easy access to a loading dock plus covered space for inventory.
A special piece of this project is a Broad Leaf Maple tree sourced by our co-worker, Randy, from his forest in Oregon. The tree was crafted to serve as a main post in the NEWwoodworks section of our CLT building. Mike W connected with this tree from delivery in OR to raising in NY. He had a few words about this post which he affectionately named, Atlas.
Next steps: We’ll be installing a Wood Fiber Insulation on the exterior of the CLT building. Another product which is new to the US, these panels offer 3.5R per inch, are FSC (Forest Stewardship Council) certified, and are another carbon sink – for each 1 m3 used, up to 1 tonne of CO2 is bound within the product. Exterior cladding, radiant heat, windows, and more will round out this new build as Spring 2017 progresses.