Mass Timber

Timber is one of the few building materials with the ability to create a closed loop, circular economy. The very existence of sustainable timber production helps reverse anthropogenic climate change. 

Population growth and urban sprawl across major centres around the globe is placing increased pressure on the need for housing and infrastructure; demanding an ever-increasing appetite for resource and finite materials. Traditional construction is responsible for anywhere up to 50% of the world’s CO2 emissions through embodied energy. In a sustainability conscious world, the construction industry is diverting its focus toward reducing the impact on waste and climate change. As our cities increase in size and height, our thirst for robust materials will continue to grow. As a result, a disconnect with nature and associated psychological impacts will intensify. Thanks to technological advances and continuous improvement in manufacturing, one material has emerged with the opportunity to reverse this trend and is gaining international recognition as the solution to our modern day needs: mass-timber construction. MASSLAM utilises massive sections of glue laminated timber in structural applications – replacing finite materials such as concrete and steel.

Having significantly lower embodied energy to produce a solution, combined with CO2 sequestration during growth, mass-timber is truly ‘better than carbon neutral’. The amount of CO2 stored within one cubic metre of MASSLAM after embodied energy is deducted equals approximately 673kg. A 1,000 cubic metre project will store 673 tonnes of CO2 and can be regrown in as little as 5 minutes in Victorian forests. Sustainable forest certification ensures the forests are responsibly managed in perpetuity and with fewer lasting environmental impacts, the construction industry can now be the answer. Better still, MASSLAM used in visual applications doesn’t just look great but adds to biophilia in the built environment – helping humans feel more connected to nature and subsequently creating happier workplaces, increasing productivity and lowering stress.

According to detailed studies by WoodSolutions, commercial structures built with mass timber offer cost savings over concrete and steel. Speak to your MASSLAM specialist for the detailed report.

Consistently installing faster than traditional construction, recent mass timber case studies comparing multiple projects in Australia have shown up to 30% faster construction times. Much of this can be attributed to early services rough-in and assembly. This speed and efficiency comes from the fact that mass timber is lighter, easier, safer to handle and install than concrete and steel. Speed of construction is a substantial consideration in cost assessment due to time related expenses such as crane and other plant hire; wages for on-site workforce; insurance premiums; permits and certifications. The reduced program offered by timber structures can also enable time critical projects to be realised. This can be a crucial consideration for many projects, including schools and student accommodation buildings, for which funding periods can be set and term dates fixed.

The constructibility of mass-timber buildings are safer in general. Tier 1 builders are reported as stating many projects show no Lost Time Injuries. Part of the reason for this is the elimination of on-site risks with prefabrication. Prefabricating or pre-attaching connectors in an automated assembly off-site before delivery reduces the need for working at heights as well as the time required to assemble. Smaller and easier hand tools are utilised, as are smaller crews. Additionally, there is less need for welding or hot works, easier anchoring of safety harnesses, the ability to pre assemble safety barriers and eliminate live-edges before craning.

All MASSLAM members uniquely pass through the world’s largest four-side planer to ensure clean surface and squareness before machining. ASH’s Hundegger (CNC) then machines to within +/-1mm accuracy to the parameters drawn out in earlier 3D design model. With the ability to efficiently and automatically process up to 1,300 x 450mm end sections, MASSLAM does not need to be block laminated. Block laminating requires two halves (or more) to be CNC profiled and then joined together – often creating misalignment of profiles and negating the millimetre accuracy of the CNC or four-side planer. ASH’s process eliminates this risk. Given some MASSLAM products are ~40% stronger than international mass-timber, we can negate the need to design with members thicker than 450mm or to block laminate. Comparatively, concrete and steel tolerances can be +/-15mm. The benefits of accuracy in MASSLAM are far and wide but can be critical for air tightness, installation, energy efficiency, constructability and overall building performance.

MASSLAM is 18% the weight of concrete and 80% the weight of steel for the same structural requirement. This means there is less need for expensive foundations. It also means more material can reach site with fewer deliveries. Lifting is quicker and can be done with smaller cranes. Less noise, dust, vibrations and truck movements result in less disruption of neighbourhoods and existing activities or tenants.

Mass timber buildings can be safer than traditional builds under fire, particularly when related to sprinklered buildings. Large sections of timber are very hard to burn. Imagine trying to start a campfire with a large log!?! (You can’t). Even under extreme fire, MASSLAM has calculable performance and maintains structural integrity. As MASSLAM is exposed to fire, a level of char is created on the fire-affected surface while maintaining structural strength behind this ‘char layer’. The structural strength is directly proportionate to the unaffected wood. Concrete with steel connections can buckle under the same heat.

MASSLAM is independently fire tested under load and for char against AS1530.4 for up to 120 minutes. With the char rate being predictable and known, designing for fire to meet the code can be as simple as adding a sacrificial char layer equivalent to the FRL requirements. For example, if a 300mm x 300mm MASSLAM 45 column in a commercial building is required to achieve a FRL of 60min, the column could be supplied in one of the following options:

• Additional wood fibre equivalent to 60 minutes on each fire-exposed surface of the post. Becoming 360 x 360mm
• 300 x 300 + two layers of overlapping fire proof plasterboard (meeting the DtS provisions of the NCC)
• Using a fire engineers ‘Performance Solution’

Find out more

Design for Manufacture & Assembly (DfMA) is a type of design process that considers the manufacture and assembly of building components for optimal speed, safety and quality of a build. Prefabrication and off-site assembly will benefit a build but requires a complete change in thinking. Design teams are required to put in more work up front so that the desired prefabrication and assembly efficiencies can be realised. Buildings cannot be partially designed before fabrication – prefabrication of each element is governed by the digital 3D design model. The building must be considered 100% complete before processing. There can be no change of design once manufacturing has commenced. An example of the benefits of DfMA is shown below.

The process begins with your concepts or plans where ASH offer a free schematic design service or a basic ‘reverse engineered’ guide of various products to narrow in on the ultimate outcome for the clients’ needs. Once the MASSLAM products and system are selected, the engineering team create a digital 3D model detailing all of the chosen components with intricate details including connection types, sizes, screws, CNC requirements and the exact locations of every detail. Potential issues with the plans can be addressed during this detailed 3D model by the engineering team – rather than being fixed on site by an expensive labour force or holding up the critical path.

Once the client signs off on the 3D model the structure is considered ‘effectively built’ and cannot be altered. This information feeds the MASSLAM automated production and CNC line where coatings, attaching of connectors and labelling of each member ensures superior on-site installation efficiencies. ASH store the finished goods and can even deliver in order of lifting sequence (subject to prior approval).

Get in early. Do not design too far down the path before talking with your MASSLAM specialist. MASSLAM is available in uniquely high strength materials that can offer:

• cost savings
• smaller columns with increased usable floor space 
• larger grids with fewer columns per floor
• alignment with basement parking (eliminating expensive transfer slabs) – ie – 9x9m, 9x12m or 12x12m
• shallower beams for additional ceiling heights
• longer spans without lowering ceiling height
• additional joint strength for smaller and more competitive connectors
• less overall weight resulting in reduced foundations
• In some cases, additional levels
• improved fire performance
• local (Australian) supply and compliance

All construction materials require unique consideration of their strength and weakness in order to maximise cost efficiency. MASSLAM can be the most cost effective of all systems but this may not be the case if you design for concrete or imported mass timber and hope to compare price. It is for these reasons why it is imperative to get your MASSLAM specialist in early. See Design and Construction chain below.

The MASSLAM line operates the largest and most efficient glulam CNC in the world with precision accuracy. This machine can process end sections up to 1,300 x 450mm with millimetre accuracy in one automated pass. The Hundegger K2i has over 160 tools and 6-axis machining. Tools available include saws, chain saws, routers and drills – to name a few. Tools chosen for use are determined by the 3D model and construction requirements.

Download the full CNC Machining Capability Brochure

Prefabricated floor assembly, our Advanced Timber Composite Floors (ATC) are ASH’s mass timber flooring solution. ATC provides a DtS pathway for fire which allows you to visually express the soffit – all while spanning further with less resource and at a more competitive rate.

ATC can often be known as TCC (Timber Concrete Composites). These systems are efficient in the construction of modern multi-storey mass timber buildings because of their higher strength and stiffness-to-weight ratios, larger span-to-total depth ratios, higher in-plane rigidity, and acoustic, thermal, and fire performances when compared with the conventional timber-only system (Ceccotti, 2002; Dias et al., 2016, 2018; Yeoh, Fragiacomo, De Franceschi & Heng Boon, 2011).

CNC Machining makes for efficient and attractive profiling of members but they also cater to an infinite number of connection possibilities. These include concealed dovetail connections, birdsmouth connections, steel plates, mortise and tenon joints pilot screw holes, char plugs and processing for all proprietary connection types. Talk to your MASSLAM specialist about preferred connection types specific to your project objectives.

MASSLAM members can be coated or stained to meet the design intent. Critically, coating is required to protect members from damage due to variations in humidity or exposure to UV and weather. The MASSLAM line is equipped with a coating line or moisture permeable wrapping to allow members be delivered with at least one protective option before delivery. Final coats are required after installation for adequate protection.

For more detail, see the MASSLAM Design Guide and MASSLAM Coating Guide.

Advanced Timber Composite Floors (ATC) are ASH’s mass timber flooring solution. ATC provides an aesthetically pleasing validated performance pathway for fire which allows you to visually express the soffit – all while spanning further with less resource and at a more competitive rate than Cross Laminated Timber (CLT).

ATC is arguably the most attractive mass timber flooring solution and tested to comply with Australia’s strict fire and acoustic requirements. ATC is a hybrid flooring system utlising MASSLAM, shear connections and a reenforced concrete screed to create an unbeatable composite floor which utilises each material’s strength in a complimentary way.

• Panelised supply for speed of construction

  • Or componentised for assembly on site if freight is a concern

• Increased acoustic damping

• Flexibility in bearing location (above, half-lap, level with the primary’s)

• Benefit of running services parallel or concealing services

• Furniture quality timber, visual grade finish

• An improved use of resource. >3x less timber than Cross Laminated Timber (CLT) for the same solution.

• Has validated performance pathway rather than performance solution for fire, providing a simplified approach for performance-based solutions.

  • (with a visually expressed soffit)

• Longer spans (the likes of conventional steel/concrete structures).

• Eliminate transfer slabs.

• Enhanced acoustic performance (less additional materials)

• Enhanced vibration performance

• Enhanced durability during construction with in-built temporary drainage solutions

ASH’s first ATC floor system is a TCC (Timber Concrete Composite) using our MASSLAM beams. These systems are efficient in the construction of modern multi-storey mass timber buildings because of their higher strength and stiffness-to-weight ratios, larger span-to-total depth ratios, higher in-plane rigidity, and acoustic, thermal, and fire performances when compared with the conventional timber-only system (Ceccotti, 2002; Dias et al., 2016, 2018; Yeoh, Fragiacomo, De Franceschi & Heng Boon, 2011).

At ASH we are constantly looking to develop our capabilities and innovate such that we can supply the market with high quality solutions that help drive the industry forward. As ASH’s ATC range develops, not all of the solutions will be TCC.

ASH have undertaken >$750k worth of research and Development in preparing ATC for market. Tests include: 

• Understanding the performance of varying shear connection types, their cost efficiency and failure modes 

• Composite action 

• Long term serviceability  

• FRL 

• Char 

• Acoustic performance and modelling of various iterations – including build-ups above and below 

• Service penetrations