A REVOLUTION IN STRUCTURAL TIMBER GRADING Douglas Gaunt 1 ABSTRACT; New Zealand has seen a transformation in the way it produces structural timber with the widespread adoption of machine stress grading along with the introduction of third party auditing. In conjunction with this the opportunity arose to align the properties of forest resource with the design demands of light timber framed houses. The final outcome of these changes has considerably enhanced New Zealand’s structural timbers reputation KEYWORDS: Structural timber, Machine grading, Quality Control, Timber design 1. INTRODUCTION Over the last ten years New Zealand has seen a transformation in the way structural timber has been graded, marketed, used and quality controlled. Prior to 2000 the majority of structural timber was visually graded with only a few large producers investing in machine stress grading. The machine stress grading machines used were the traditional plank bending types ie. Metriguards, Computermatics and Eldeco Darts, five machines were regularly used in production with few others in storage. At this time the most common structural grades were the NZ visual grades of Engineering No 1Framing & No 2 Framing grades with Carter Holt Harvey having recently introduced the Australian MGP10 grade into New Zealand called Laserframe The application of quality assurance (QA) to structural timber was in its infancy with the two large producers (Carter Holt Harvey and Fletcher Challenge) using in house output control systems. However the QA procedures did not have an independent third party auditing component. Scion had undertaken several large evaluations of the NZ Radiata pine resource and it had become apparent that the simple introduction of the Australia MGP grades (MGP10, 12 & 15) would not be the best solution. The MGP grading system was developed in Australia specifically for the machine stress grading of pine. did not match well the strength and stiffness properties of the NZ Radiata pine resource however the principle behind the MGP grading system was still valid. In terms of the structural use of Radiata pine particularly in house construction, the grade of choice for tens of years had been No1 Framing, this was assigned a Modulus of Elasticity (MoE) of 8GPa. The housing builders and developers had a long history of what timber was needed where and the costs to build a house. Structural timber had also received some bad press with the prosecution of a major producer over its failure to produce timber with the required structural properties. 1 Scion, Private Bag 3020 New Zealand. douglas.gaunt @scionresearch.com To address all these issues it became apparent that significant changes would be required if NZ wanted to lift structural timbers reputation both within NZ and internationally. This could only be done by keeping within a tight series of financial and end user impact constraints. These being: • The need to fit the structural grades around the actual properties of our current and future Radiata pine resources. • A form of quality assurance focusing on output control of structural properties as opposed to machine control complete with third party auditing. The application of the QA procedures had to be made as simple and practical as possible if widespread adoption was going to occur. • Any new structural grades could not afford to significantly alter the way houses were built or more importantly the cost to build a house. • Was it possible to bring in new grading technologies that reduce both the capital and/operational costs whilst providing enhanced returns to the wood processor?. The Approach taken to address this case is outlined as follows • Structural grades – the development of new structural grades link forest to end use. • NZS3622 Structural property verification – the introduction of quality control and third party auditing. • New Acoustic grading technology, • A summary of the changes as of 2012. Presently in New Zealand work is underway on a model that can take all the following inputs: site, silviculture, age, genetics, log form and position in tree, distribution of branches, Sawing pattern, Piece position in Log, etc.. to make gross predictions of structural grade recovery. A fully integrated model such as this may in fact not be achievable without the allocation of huge resources (many millions of dollars). However we do have a good understanding on what variables affect the outturn of structural grades. In broad terms the following Figure 1 shows the key factors that influence lumber grade recovery (and wood quality in general). Site Silviculture Fertility etc.. Thinning Stocking Branch Size etc.. Wood Quality Lumber grade recovery in this case Age of Harvest (20,30 or 40 years) Genetics Wood Density Growth rate etc.. Figure 1: Key Factors affecting Wood Quality It is unlikely that a model will ever exist that can reliably predict the strength and stiffness values of individual boards. Accordingly the approach required is to select/grade at several points along the processing chain. Several nationwide studies were undertaken exploring the stiffness and strength properties of radiata pine [1,2,3,4]. These studies generally involved purchasing visually graded timber in the No1Framing and No2 Framing structural grades The timber was then checked for visual grading accuracy, machine stress graded and then tested for bending strength and stiffness In 1999 Figure 2 [1] was produced which showed the relationship between the bending strength/stiffness and the Australian MGP & F grades and the then suggested MGP6 & 8 grades. Figure 2: 1999 Grade relationships 150x50 and greater 100x50 and smaller Key Characteristic Bending Strength, MPa 2. STRUCTURAL GRADES. Structural lumber requires quantitative performance measures of stiffness and strength which designers can use with confidence. Traditionally these properties had been provided for through a set of visual grading rules which were linked to a set of characteristic grade stresses. However the grade recoveries in visual grading were declining and visual grading did not directly measure stiffness – Visually graded No.1 framing not always well graded. Surveys (Forest Research, Consumer Institute) found serious percentages of pieces out of grade within packets. generally the most important characteristic in timber design [1]. 45 MGP 15 40 F14 Present 'F' grades 35 Present 'MGP' grades F11 30 Bulk of Resource 25 F7 20 MGP 12 F8 MGP 10 F5 15 F4 MGP 8 MGP 6 10 Proposed 'MGP8 & 6' grades 5 0 4 6 8 10 12 14 16 Modulus of Elasticity GPa Data points shown represent recent Forest Research radiata pine structural evaluations In Figure 2 New Zealand Radiata pine can be broadly characterised by its relatively high stiffness for a given strength or conversely a lower strength for given stiffness. This characteristic also agrees with the rationale behind the development of the Australia developed MGP grades (MGP10, 12 & 15). Previously Australian pine had been graded into the F grades that historically were developed for Australian hardwoods which have a high strength for given stiffness. Using the F grade system on Radiata pine usually resulted in the strength properties being achieved but the stiffness properties being well exceeded. As stiffness is commonly is the key factor in design the structural properties of pine were not then being fully utilised. Secondarily the NZ Radiata Pine structural timber resource was found to have an average stiffness of 8GPa. Taking into account that NZ had an extensive history of building houses with No 1Framing (MoE = 8GPa) it was logical to take the Australia MGP system and extend it lower. Thus two new machine stress grades (MSG) based on MoE’s of 8 & 6GPa were developed. Ultimately the final NZ MSG grades became MSG 15, 12 10, 8 & 6 (Table 1). In the development of any set of structural grades, it is important that there are enough grades to cover the extremes of the current and future forest resources. It is accepted however that in practice market and production constraints will limit the sawmill to only producing three or possibly four grades at any one time. The obvious driver for the sawmiller/forest owner is to produce more timber in the higher and more valuable grades, but if that is not always possible then there is a lower but still useable grade available. It is important to realise that lower grades will not always result in proportional increases in timber volumes in a structure. For instance in a beam situation limited by stiffness an increase of 10% to the beam depth will compensate for a 25% reduction in the Modulus of Elasticity One study [4] took correctly graded No1 Framing from six mills around NZ (Figure 3) and in conjunction with the bending strength and stiffness data determined the characteristic bending strength and stiffness values. Mill C Mill B promotion of machine stress grading which actually provides direct measure of stiffness. It was however accepted at the time that the visual grading would still play apart in NZ construction but would more and more limited to larger sizes and the smaller producers. This study provided further confirmation that Radiata pine has a lower strength for given stiffness (Figure 2) This information lead to the 1999 [1] study which looked at revising the strength to stiffness relationships. Mill A Mill F Mill E Mill D Figure 3: Location of study timber Figures 4 and 5 show characteristic bending strength and stiffness for the sample of correctly graded No 1Framing 150x50 timber. In terms of bending stiffness there was a 4GPa difference across the country with 5 of the 6 mills achieving the No1 Framing grade value of 8GPa. In terms of bending strength only two of the mills achieved the No1 Framing grade target value of 17.7GPa. 150 x 50 Bending Stiffness 10 9.195 8 7.736 8.313 8.089 8.083 Target Stiffness 8.0 GPa 6 5.743 Key 4 25% 2 Ek 0 Mill A Mill B Mill C Mill D Mill E 50% 75% Mill F Confidence band Bending Stiffness Ek, (GPa) 12 Figure 4: No 1Framing bending stiffness 150 x 50 Bending Strength 26 23.23 22 21.27 20 18 16 19.35 17.32 14.68 14 12 12.04 Target Strength 17.7 MPa 18.47 16.40 13.95 15.47 15.67 15.98 14.37 13.13 11.59 12.34 10 10.28 9.23 8 Key 25% 6 4 Rk(0.05) 2 0 Mill A Mill B Mill C Mill D Mill E Mill F 50% 75% Confidence band Bending Strength Rk, (MPa) 24 Figure 5: No 1Framing bending strength This trend of wide variations in bending stiffness within a single visual grade further confirmed the widely held belief that visual grading cannot reliably grade for stiffness. The solution here was to continue with the Stiffness to strength relationships Traditionally the approach taken in setting the strength properties of structural grades has been to carry out an extensive strength testing program across the forest resource over a range of sizes. The test data in conjunction with the grade data is then analysed to determine the strength values. The published strength values can have a degree of conservatism built in them over the test data. Usually it is only the foresters and producers plus the researchers that are involved in this process but ironically none of these parties actually use these values, for the producers they are just a set of performance targets to be achieved. It is the design engineers that use these values and directly see the impact in their designs. Hence the approach taken in setting the new grade stresses had three drivers. 1. What were the actual strength properties of the forest resource as determined by test. 2. How low could the strength properties relative to the stiffness values be set without significantly influencing the design and ultimately the volumes of timber required to build houses. In timber design it is very common to hear engineers taking about stiffness limited design. The implication here is that strength is being over achieved. 3. To make the in-mill quality assurance strength testing less onerous. NZS3604 New Zealand’s light timber framing code currently sets the timber sizes needed for given spans and loadings. Using NZ3604 as the design client a study was undertaken where the strength properties were lowered (keeping stiffness unchanged) until a point was reached where strength was becoming a design limitation. At this point stiffness was still the predominant governing design factor but without the excessive reserves in strength, this approach resulted in the majority of member allowable spans remaining unchanged. As an example the spans in NZS3604 were based around the old No1 Framing grade had a bending stiffness of 8GPa and bending strength of 17.7MPa, Whereas the new MSG8 & VSG8 grades (Tables 1& 2) have the same stiffness but a lower bending strength of 14MPa. This 3.7MPa reduction did not significantly changes the span tables in NZS3604. One of the downstream benefits that was quickly realised was that with the lower strength target it became a lot easier for the wood producers to satisfy the bending strength verification target. In general on observing the implementation of product Quality Assurance if the acceptance targets are low enough that a producer commonly gets a QA pass then the barrier limiting widespread adoption of product QA with third party auditing is significantly reduced. Another issue that needed to be addressed was to link the availability of the timber grades and sizes to the designers. Without this link a grade size combination can be easily selected by the designer that is not produced or not readily available in close to the location of the structure. This incorrect selection can hold up the building consent process if the design needs to be reworked. For example in New Zealand; • MSG15 will be very rare, if available at all. • MSG12 availability will be limited in volume, dimension and by region • MSG10 tends to be used in timber trusses but will be limited in volume, dimension and by region MSG8 has become the grade of choice for light timber, and it is widely available around NZ • MSG6 is not that common as many producers use that grade for their re-manufactured products. • VSG10 will be virtually limited to Douglas fir • VSG8 is more common in the wider sizes but does require additional effort in terms of a knowledge of forests, log sorting, cutting patterns, with stricter limits on visual characteristics to achieve the required properties. A lot of VSG producers have now switched to being MSG producers This is ongoing educational process via industry presentations, and one of one discussions. • Table 1: Characteristic stresses for machine graded timber NZS3603 A4 Species Grade Radiata Pine & Douglas Fir MSG 15 MSG 12 MSG 10 MSG 8 MSG 6 Moisture Content – Dry (m/c = 16%) Bending Compression Tension Strength Strength Strength MPa 41.0 28.0 20.0 14.0 10.0 MPa 35.0 25.0 20.0 18.0 16.0 MPa 23.0 14.0 8.0 6.0 4.0 Bending Stiffness GPa 15.2 12.0 10.0 8.0 6.0 Lower bound Bending Stiffness GPa 11.5 9.0 7.5 5.4 4.0 Table 2: Characteristic stresses for visually graded timber NZS3603 A4 Radiata pine & Douglas Fir Bending Strength VSG10 VSG8 No 1Framing MPa 20.0 14.0 10.0 G8 No 1Framing 11.7 7.5 1. Moisture Content – Dry (m/c = 16%) Compression Tension Strength Strength MPa MPa 20.0 8.0 18.0 6.0 16.0 4.0 2. Moisture Content – Green (m/c = 25%) 12.0 4.0 11.0 3.0 Bending Stiffness GPa 10.0 8.0 6.0 Lower bound Bending Stiffness GPa 6.7 5.4 4.0 6.5 4.8 4.4 3.2 3. NZS3622 PROPERTY VERIFICATION Visual grading history Historically in New Zealand structural timber was only visual graded primarily using features like knot size and location, presence of pith, sloping grain etc.. Different rules existed for the different grades and sizes. The common visual grades were No 1Frame and No 2Frame visual grades, the Engineering grade has all but ceased to exist due lack of timber that satisfied the strict requirement on knot size. As previously noted visual grading has the ability to grade for strength but not stiffness. The visual graders have to be trained and have to achieve grading accuracy targets; however there was no requirement for checking for the final graded strength and stiffness properties. Machine grading history The early producers of machine grade timber used a set of machine grade threshold developed for the ‘F’ grades in NSW in 1974. The producers then applied a visual override that was largely specific to the individual producers. The different producers developed their own in house methods to control the quality of the machine graded timber. These methods did not always have a feedback loop back to the machine stress grader to allow adjustments to be made to the threshold settings. In the early 2000’s a large timber producer was found to be selling timber that did not have the claimed structural properties. This issue was almost certainly not just limited to this one company particularly as the majority of timber sold in NZ was visually graded without any property verification quality control. It has long been recognised the importance that the end users of structural timber must have confidence in the timber products. Their design and structures rely on the fact that timber used has the properties claimed for it, if not the structures may not perform in service as intended. If the timber industry could not provide this confidence there was a real risk of market share decline. Taking all this issues into account it became apparent that New Zealand had to develop a property verification method in the form of a NZ standard. The key features it needed to have were: • It must provide some form of guarantee of structural properties. • It must use output control not machine control. The emphasis must on the quality of the final product not the procedures used to produce the final product. There must be flexibility in the grading methods used but consistency in the property verification. • It must be easy to implement and manage in sawmill situation. • It must be acceptable for timber exports to Australia. • It must incorporate third party auditing. • • There should some incentive for producers to enter into a property verification scheme. It needs to be applicable to both visual and machine graded timber. The actual verification checks must be the same. It should be acknowledged that the wood processing industry were initially wary of third party auditing but when it became apparent that it was possible to continually satisfy the requirements of NZS3622 without disruption to production, third party auditing was universally accepted and has become a significant marketing benefit. The initial approach was to look at the verification method used Australia AS/NZS4490. This was rejected as it did not have provision for third party auditing. Accordingly it was decided to develop a new NZ property verification standard (NZS3622), this standard would be limited to structural timber only as other structural timber products such as LVL and Glulam have their own standards. The approach taken in NZS3622 was; • Adopt a target bending stress as being an estimate of the property value determined with 75% confidence that would be exceeded by 95% of the product. • Adopt a target mean stiffness as an estimate of the mean value. • Adopt a target 5th percentile stiffness as being an estimate of the property value determined with 75% confidence that would be exceeded by 95% of the product. For bending stiffness this resulted in a rolling 30 piece average which is monitored to be above the target. In practice the target has been set at 0.5GPa above the assigned characteristic grade value. The lowest recorded stiffness value in the previous 30 test results is taken as the 5th value which must be above the assigned lower bound grade value. For bending strength producers had the option of testing timber to destruction to determine a 5th percentile or proof loading to the characteristic grade stress. Most producers favoured the proof loading approach as less timber was broken. The acceptance criteria is that no more than 1 piece in a sample of 30 could fail the proof load test and none shall fail at less than 90% of the characteristic bending strength. NZS3622 also sets out • Requirements around the initial evaluation • Requirements for the audit organizations • Sampling procedures • The information needed to be displayed on the timber • Product release procedures If a company chose not to verify their timber due to the fact that they were either a very small producer or producing a single batch of timber then an unverified option existed. This being that the design properties of the unverified grade where reduced to level whereby there was confidence that the grade properties were still going to be achieved. This grade is No 1 Framing (Table 2). Since the introduction of NZS3622 in 2004: 1. NZS3622 as has been recognised as acceptable solution for timber being imported into Australia. 2. The wood processing industry has developed a standard operating procedure (SOP) that deals with the issues around the implementation of NZS3622. This group comprise of the auditors, industry representatives and researchers. To date this has been very successful in ensuring everybody has the same performance targets and code interpretation. Ultimately the requirements of the SOP will be included in a revision of NZS3622 3. Under NZS3622 the industry has now tested several hundred thousand pieces of timber; many companies have linked this data back to log and forest to enhance their financial returns. 4. Two new auditing companies have been established and two others have broadened their scope to include NZS3622. 5. Over 90% of structural timber is now third party verified compared to 0% pre 2004. 4. In order to continue to promote the uptake of machine stress grading over visual grading it was seen that • A new low cost machine stress grader was needed. • Higher production speeds were important. • A more flexible machine would be beneficial. • The new grader must offer a financial benefit over both visual grading and the traditional machine stress graders. A-Grader Scion in partnership with Falcon Engineering developed a machine stress grader, the A-Grader which measures the stiffness of timber via acoustic waves. The traditional machine stress grader relied on the timber being passed linearly through the machine grader, the AGrader however graded the timber when it was travelling laterally in a lug chain. The advantage of this approach was that the timber was travelling slower for the same throughput and lug chains existed in both green and dry mills. The most significant was that the A-Grader could machine stress grade both green and dry timber, rough sawn and planed, a wider range of sizes, random width, depth along with random lengths. Its installed capital cost was less than new plank graders with the installation costs being significantly lower than a traditional linear grader. Figure 6 shows a typical A-Grader installation NEW ACOUSTIC MACHINE GRADING TECHNOLOGY Scion from the 1980,s onwards has long been pushing the benefits of machine stress grading over visual grading as the optimum form of structural grading. It has long been noted that visual grading [1] does not directly measure stiffness – generally the most important characteristic in design. It is the stiffness properties that control the allowable spans for the majority of light timber framed structures covered by NZS3604 At the same time the grade recoveries in visual grading had declined as evidenced by the fact that the highest visual grade (Engineering Grade) had all but disappeared for the structural market. In 2000 there were approximately 7 machine stress graders operating in NZ these were a mix Metriguard’s Eldeco Darts and Plessey Computermatics. Most companies considering installing a machine stress grading were attracted to the Computermatics due their second-hand availability from Australia and Europe. A second-hand machine could be purchased and installed for under $NZ100,000. The issue at the time with the Computermatics was that the technology was originally developed in the 1960/70’s with a solid state control unit. The solid state control unit was generally reliable but it used components that were no longer produced and hence irreplaceable, mechanically replacement parts were usually available from scraped machines. Figure 6: A- Grader (cover removed) Prior the development of the A-Grader Scion undertook a machine grader comparison study [5] in which the same batch of timber was machine graded by a range of traditional plank graders in sawmills and then using a range of laboratory techniques. After grading the timber was tested for its bending strength and stiffness in accordance with AS/NZS4063:1992. The key outcome of this study is best shown in Figure 6 which plots the 30% 380 25% 360 20% 340 15% 320 10% 300 5% 280 0% Value Recovery $/m 3 400 Value Recovery Average Grade CoV% value recovery and average coefficient (CoV%) of bending stiffness for each of the grading operations. Essentially as the CoV reduces the accuracy of grading increasing and the value recovered increases (more timber into the higher more valuable grades). Average Grade CoV% Figure 6: Value recovery vs grading machine This outcome has since been realised by the operators of acoustic grading machines. Since the introduction of A-Grader the use of acoustic machine stress grading technology has been widely adopted in NZ where it is now estimated that over 50% of the structural timber graded in NZ is done by acoustic machine graders. 5. 1. 2. 3. 4. 5. 6. 7. 2012 UPDATE. The number of machine stress graders in use in NZ is now approximately 40 up from 7 in 2000. With the majority of timber now sold as machine stress graded Well over half the machine stress graders in NZ production are Acoustic graders. All the companies producing MSG timber are part of the NZS3622 property verification scheme. NZS3622 is now an acceptable solution under the Australian machine grading standards. This has resulted in NZ being able to export structural timber (verified in NZ) to Australia. The majority of the visual grading processors are part of the NZS3622 property verification scheme. The exception generally being those small producers who could neither afford to enter a property verification scheme or have chosen not to but are happy to sell their products as unverified No 1Framing grade. The wood processors have endorsed the NZS3622 verification system with its wide spread adoption and have quickly realised the benefit of third party auditing. In doing so they have gained a great deal of knowledge linking log supplies to product properties. The wood processors have jointly developed standard operating procedures around the implementation of NZS3622. 8. The most common grade sold in NZ is MSG8 which is a natural fit with the forest resource and the house construction. 9. The house building standard NZS3604 has been modified to incorporate the new verified and the unverified grade, there has been negligible impact on volumes of timber used in houses. 6. CONCLUSIONS This significant transformation has taken place by: • Ensuring that the science was connected to industry application. • A high degree of engagement and support from the wood processors, the regulatory bodies and the end users. • The matching of structural properties of the forest resource to the design requirements. • The provision of a better grading technology. It is suggested that without addressing all these issues together this change would not have taken place as quickly and would not have been so universally accepted. In summary the structural timber industry is now in a very strong and united position with the ability to produce verified structural timber making best use of the forest resource. The reputation of NZ graded Radiata pine has been considerably enhanced and the future will be much more assured. ACKNOWLEDGEMENTS The author wisher to acknowledge all parties involved in making this transformation to the structural timber industry. Namely: Fellow researchers at Scion, BRANZ, Standards New Zealand, Falcon Engineering and most importantly the timber industry itself. REFERENCES. 1. Gaunt, D. J., Roper, J., Davy B., 1999, Performance Grading Of New Zealand Pine and The Development Of The ‘E-Grader’, Proceedings of the Timber Industry Federations AGM, November 1999. 2. Collins M, Gaunt D, Roper J, 2000, MGP8 – Can it be substituted for No 1Framing in NZS3604?, Wood Processing Newsletter, Issue 28, December 2000. 3. Walford, G.B, 1996: An In-Grade Evaluation of Machine-Graded New Zealand Radiata Pine. Proceedings of the International Wood Engineering Conference, New Orleans, USA, Vol. 2, pp 287-292. 4. Strength and stiffness of visually graded radiata pine in large sizes, Revised September 1997. Value Recovery Report 5. Machine Stress Grading Technology Evaluation Part 1: Machine Evaluation A Multi-Client Report: Forest Research. 6. AS/NZS AS 4063:1992: Timber - Stress graded In-grade strength and stiffness evaluation, Standards Australia/Standards New Zealand. 7. AS/NZS AS 4490:1997; Timber - Stress graded – Procedures for monitoring structural properties. Standards Australia/Standards New Zealand. 8. NZS 3631:1988. New Zealand National Timber Grading Rules, Standards Association of New Zealand. 9. NZS 3603:1993 A4. - Code of practice for Timber Design, Standards Association of New Zealand, 10. AS1720-1997, Part 1. Timber Engineering Code, Standards Association Of Australia 11. NZS3622:2004 Verification of Timber Properties, Standards New Zealand.
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