A MODULAR TIMBER CONSTRUCTION SYSTEM MADE WITH HOLLOW-BOX ELEMENTS

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1 A MODULAR TIMBER CONSTRUCTION SYSTEM MADE WITH HOLLOW-BOX ELEMENTS Roman Hausammann 1, Steffen Franke 2 ABSTRACT: Timber hollow-box constructions made with solid wood planks are well established as suspended floor structures or roof structures. The application as wall construction is neither known nor used in multi-story timber buildings. A comprehensive timber construction system, as hollow-box constructions, which can be used in residential houses as well as multi-story buildings was developed, was optimized for the Minergie-Standard and will be established. Furthermore, an organizational and cost-efficient definition of a new business model allowing smaller timber businesses access to the residential building market. Finally the structural and failure behavior as well as the load capacity was investigated and compared by numerical and experimental tests. Due to the glued box-systems, the elements show a very stiff behavior with a dominant failure in shear which can be predicted very well easily. KEYWORDS: eggo timber construction system, business model for timber construction companies, timber hollow-box 1 INTRODUCTION 12 Houses or multi-story buildings consist of different structural elements which can be efficiently prefabricated as sections, as shown in Figure 1. They have to transfer different loads and they are usually made by different structural systems like timber frame panels, box systems or solid wood panels. Roof element Floor element Interior wall element Exterior wall element Figure 1: Elements of timber houses, principle loading situation for floor and wall elements (zur Kammer 2005) 1 Roman Hausammann, Bern University of Applied Sciences, Architecture, Wood and Civil Engineering, Solothurnstrasse 102, 2504 Biel, Switzerland. roman.hausammann@bfh.ch 2 Steffen Franke, Bern University of Applied Sciences, Architecture, Wood and Civil Engineering, Solothurnstrasse 102, 2504 Biel, Switzerland. steffen.franke@bfh.ch However, timber hollow-box constructions made with solid wood planks are well established as suspended floor structures or roof structures. The application as wall construction is neither known nor used in multi-story timber buildings. Therefore a comprehensive timber construction system which can be used in residential houses as well as multistory buildings was developed and will be established. The system is based on the principles as for hollow-box constructions. Different static and physical requirements such as load carrying behavior as bracing elements or the heating insulation, depending on the application need to be considered. Using the construction system as external wall, it has to be optimized in aspects of thermal insulation and cost-effectiveness. Thus the Swiss Minergie-Standard, comparable with a low energy house standard, and a production costs comparable to conventional systems are aimed. Another main objective within the project was to develop an organizational and cost-efficient definition of a new business model. The results provide smaller timber businesses with access to the residential building market. Value is created within a network of small companies, on the basis of processes arranged in a flexible, modular fashion. The hollow-box construction technique is predestined for this kind of new business model and guarantees cost-efficient implementation.

2 2 BUSINESS MODELL 2.1 NEW BUSINESS MODEL FOR SMALL TIMBER CONSTRUCTION COMPANIES The research project, supported by the Commission for Technology and Innovation of the federal government, is investigating solutions for timber construction companies with the eggo timber construction system. On one hand the development of a system with the timber-box construction technique shall enable firms to construct individually designed buildings with standard and supplementary elements, see Figure 2. On the other hand through this flexible model for value creation the firms can decide individually which services they will perform themselves and which ones they will outsource to the system owner. The project considers six phases for value creation, as shown in 1. Planning/Construction design 2. Production of standard timber hollow-box elements 3. Production of supplementary components 4. Automatic pre-cut of hollow-box elements, beams, panels, etc. 5. Production of panel elements at the factory 6. Assembly and preliminary building works on the building site Figure 2: Process design as a foundation for the new business model The model can be adjusted depending on the capacity of the firm regarding number of employees, infrastructure and know-how. This enables smaller timber construction companies to do new construction and persist in the market. The timber construction sector is expected to create new momentum concerning the marketing of multistory timber construction. The timber cavity technique is currently being used for ceiling and roof elements and shall find its application as wall elements with the eggo system. It is predestined for a cross company implementation with flexible value creation. The system allows the construction of multi-family housing up to four stories high. The firms increase their profitability through targeted application of their resources and through maximizing their capacity. 2.2 SWISS CONSTRUCTION INDUSTRY - SITUATION AND MARKET RESEARCH New construction is one of the biggest sectors of the Swiss construction industry. Especially the construction of multifamily housing has proven to remain constant at a high level. This is caused on one hand by the low interest rate for mortgages as well as the elevated immigration of workers. However, the market is complex: In a highly competitive market with stagnant prices and international pressure, companies must fulfill growing quality expectations of the customer. As regards to new construction, timber construction companies stand in cutthroat competition with the concrete and masonry industry. Due to the small size of timber construction firms 77% of the 2000 firms have less than ten employees - they are often lacking the infrastructure and the know-how for active involvement in residential construction. In the future small timber construction companies shall have more opportunities to realize also bigger projects and to compete successfully for new construction in the residential market. This is the goal of a research project from Egg Holz Kälin AG in cooperation with Kalt AG as well as Bern University of Applied Sciences and Lucerne University of Applied Sciences. The development of a flexible model for value creation in the context of timber cavity construction technique shall accomplish this goal. As a foundation for the development of the new business model for value creation, Lucerne University of Applied Sciences took the lead in a first step by executing an exhaustive market analysis amongst timber contractors and architects. The goal of this survey was to find out which issues are important to timber contractors and architects regarding new constructions. Specifically, under which circumstances would they be willing to use this system? 172 timber contractors and 403 architects were involved in a combination of quality interviews and quantitative questioning. 76% of timber contractors and 86% of architects replied yes or most likely, yes, when asked, if they would use the planned timber construction system. The increase in confidence in timber construction, the

3 flexibility in choosing self-performed tasks as well as a quality assured building system, which includes guarantees, were most important to the timber contractors. They also emphasized that they would be able to benefit from the know-how of the system provider, minimize their business risk and have the opportunity to offer buildings according to Minergie standards. Architects placed specific value on a quality assured system, the support of the knowhow of the system provider as well as the increase in confidence with the building owners in timber construction. These findings flow into the realization of the model for value creation as well as the conceptual design of the building system. Currently both of these issues are in development. The system is planned to be market-ready at the end of CONSTRUCTION SYSTEM 3.1 STRUCTURAL SYSTEM In comparison with the well-known timber frame panel construction, the new hollow-box wall system is constructed in a different way, see Figure 4. Vertical loads are transferred through the interior and exterior solid wood planks. Moreover the hollow-box system is more rigid due to the glued joints between all solid wood components. In both examples the airtight layer is made without an additional vapor barrier. All the joints between the elements have to be coupled together with adhesive tape to ensure an airtight building cladding. The vapor density of the whole construction is quite small. It s also called as open construction in relation of the vapor density. This kind of construction requires exact and reliable work on the building site. Furthermore all involved employees must protect the timber construction of humidity exposure. 1-Gypsum plasterboard 2-Airtight layer 3-OSB 4-Thermal Insulation 5-Wood fiberboard 6-Ventilation cavity 7-External cladding Inside Figure 3: Timber frame panel construction (Kolb 2008) Inside 1-Gypsum plasterboard 2-Airtight layer 3-Internal solid wood plank 4-Thermal Insulation 5-External solid wood plank 6-Wood fiberboard 7-Ventilation cavity 8-External cladding Figure 4: Timber hollow-box construction 3.2 MINERGIE STANDARD MINERGIE is a Swiss label for energy standards of buildings. The aim is to realize buildings with low energy consumption and guarantee high comfort for residents. To achieve the requirements of MINERGIE, it is necessary to construct building components with a thermal transmittance of U = W/m2K. To avoid an extensive calculation of the thermal heat supply, approved Minergie modules (wall, ceiling, and roof) with a thermal transmittance of 0.15 W/m2K can be used. Thus the label can be achieved easily with less effort. The use of thermal insulations with a low thermal conductivity and the reduction of wood within the construction are presupposed. For example: A hollow-box with a thickness of 280 mm, a percentage of wood of 10.5% and a 230 mm thick thermal insulation between the webs need an additional insulation layer of 22 mm (λ = W/mK) to achieve a thermal transmittance of U = 0.17 W/m 2 K. The external wall has a total thickness of 364 mm. To get a thermal transmittance of U = 0.15 W/m 2 K another 38 mm thermal insulation are necessary, cf. Figure 4. Inside the hollow-box, an insulation with a thermal conductivity of λ = W/mK is used. 3.3 PRODUCTION The process starts with a holistic construction design. Based on the production documents the standard elements will be manufactured in a small factory with mostly automatic machines, Figure 5. Pre-cut can be made by fully automatic machines or by hand machines, Figure 6. The industrial produced timber hollow-box elements are fixed together to large-sized wall elements, Figure 7. Additional insulation layers as well as different installations are prefixed in the factory according to the requirements. Afterwards wall, ceiling and roof elements 402

4 have to be assembled on the site, Figure 8. Final works such as fixing the façade or closing internal sheeting are done at the end of the timber work process. Depending on the chosen architectural style, single- or multi-family houses made by eggo construction system can appear in a various design, Figure 10. The level of input chosen by the small timber construction companies depends on their utilized capacity and their technical facilities. 4 NUMERICAL AND EXPERIMENTAL VERIFICATION 4.1 NUMERICAL INVESTIGATIONS The modular timber construction system was verified and investigated in experimental and numerical simulations. The aim was to analyze the load carrying behavior and to localize the maximum stresses and failure processes in the numerical analyses. These results will then be compared with experimental results. The numerical model considers three different load transfer systems as shown in Figure 11. Model 1 Model 2 Figure 5: Automatic fabrication of standard hollow-box elements Figure 6: Pre-cut by hand machines Vertical fixing Tension Anchorage Model 3 Tension Anchorage Figure 7: Production of panel elements Figure 9: Interior view of the kitchen on the top floor Figure 8: Assembly on site Figure 10: Outside view of the pilot project (two-family house) Figure 11: Load transfer systems Model 1 describes the situation where the load acting at the top of the element can be transferred over the full length in shear, tension and compression. In model 2, only shear and compression in combination with tension anchors at the end of the panel can be transferred. The vertical deformation at the top of the element was restricted in model 3 to simulate the fixing between the stories. For the comparison among each other, the wall system was loaded with a constant displacement of u = 1 mm at the top. The 3-dimensional numerical model is equivalent to the realistic EGGO-elements and simulates 4-box-elements 1000 mm in width, 2000 mm in length and 200 mm in thickness. The numerical model is defined with solid45 elements with 8 nodes and 3 degrees of freedom for each node. The wooden material is defined as an orthotropic linear elastic material. The material parameters for European spruce are taken according to Neuhaus (1987)

5 for a moisture content of 12 %. The stiffness of the glue line between the panels and the webs are assumed to 100 % of the corresponding material strength. The comparison between the numerical results of the three models is shown in Figure for the stress parallel to grain and in Figure for the corresponding shear stress distribution. The continuously transferred load in model 1 results in a uniform stress and deformation distribution with the smallest shear stresses. Adding the local anchorage for tension at the outer web, as in model 2 and 3, results in high stress concentrations between the outer web and the panel which would trigger the failure. In model 3, less stresses and stress concentrations could be observed due to the fixing between the storeys which would more reflect the real situation in the building. However, due to the restrictions in the testing facilities, only model 2 could be experimentally investigated and compared. Figure 14: Stress parallel to grain for model 3 Figure 12: Stress parallel to grain for model 1 Figure 15: Shear stress for model 1 Figure 13: Stress parallel to grain for model 2 Figure 16: Shear stress for model 2

6 The test setup was a three-point bending test of two wall elements connected together by two tendons in the bottom, as shown in Figure 18 and Figure 20. Prior testing, the tendons were pre-stressed with about 15 kn per tendon. The loading procedure for the specimen was according to EN 26891:1991, which describes the test procedure required for experimental tests of connections, as shown in Figure 22. This loading procedure makes sure that the connection is well settled, before the major test is done so that the effects according the fabrication and the natural slip in the connection and at the supports are negotiated. For the evaluation of the test results, the load and midpoint deflection of the beam, the indentation at the supports, the displacement between the beam and the loading plates as well as the shear deformations were recorded during the test. Figure 17: Shear stress for model 3 For the determination of the maximum load capacity of each element, the following failure strengths for European spruce are used: 40 MPa in compression; 70 MPa in tension and 6 MPa in shear. The numerical load and stressstrength ratio according to a deflection of 1 mm, the calculated failure loads and experimental results are summarized in Table 1 always given for one element. From the highest stress-strength ratio, one can see that the elements of model 1 would fail in compression whereas the elements of model 2 and 3 would fail in shear where the tension anchorage is placed. Because of the free deformation of the top of the element in model 2, it shows the smallest load capacity. Front view Anchorage with tendons Bottom view Load application by plates and dowels Side view Figure 18: Principle sketch of test setup used for shear walls Table 1: Load capacities in order to the model and stress situation Model Numerical load for u = 1 mm [kn] Stress-strength ratio [%] Compression Tension Shear Calculated failure load [kn] Compression Tension Shear Experimental failure load [kn] EXPERIMENTAL TEST SERIES The shear strength, stiffness, and the load carrying behavior of the model 2 were investigated in experimental tests series. In total ten elements in pairs of two were tested. The elements are made of European spruce. The size of the element was 1000 mm in width and 2445 mm in length. The thickness of the element was 200 mm. In detail, the panel thickness was 40 mm and the cross section of the webs was 33 by 200 mm. Figure 19: Load application and joint between two tested wall elements

7 Figure 20: Test setup for shear walls Figure 24: Shear failure between the side-panel and the outer web Figure 21: Shear wall tested, shear failure between outside web and panel Load F [kn] Figure 22: Loading procedure Load F [kn] Deflection u [mm] Deflection u [mm] Figure 23: Loading deflection curve Figure 25: Post failure at the tension anchorage after shear failure in the panel 4.3 RESULTS AND DISCUSSION The wall elements tested showed no variation in the stiffness of the elements, as can be seen in the load deflection curves in Figure 23. The failure always occurred as shear failure between the panel and the outside web at the tension anchor as shown in Figure 24 and Figure 25. The load capacity per test was in average 198 kn with a coefficient of variation of 14.6%. This results in a load capacity per element of 98.8 kn as given in Table 1. The corresponding deflection was about 40 mm in average with an opening of the joint of about 25 mm. At failure load, the tendons carried 225 kn together. The experimental results confirm the numerical failure behavior in shear between the outer web and the side panels at the location of the tension anchor. The capacity of the tested element was about 30 % higher than the numerical prediction. 5 CONCLUSION The developed timber hollow-box system as a wall construction is highly efficient in terms of statics and thermal insulation; allows prefabrication consolidating timber hollow-box constructions into a single integrated construction system; and provides the technical conditions for a cost-efficient business model that can be implemented across companies. In order to reduce the

8 settling of the building due to shrinkage, the timber implemented in the walls are arranged vertically. Sheathings and studs of the hollow-box elements are glued together with solid spruce planks. Since the width of solid wood planks without joints are limited, a narrow box grid and a stiff wall construction results. Various series of ribbed-box and hollow-box elements with one respectively two sheathings or different studs were conducted and investigated. The structural behavior, failure and load capacity could be investigated by numerical and experimental tests. Both tests show the same behavior which confirms that the load capacity of the elements can be predicted very well and easily. ACKNOWLEDGEMENT The research work was generously supported by the Commission for Technology and Innovation (CTI) of the federal government from Switzerland. The project is in cooperation with Lucerne University of Applied Sciences, Egg Holz Kälin AG and Kalt AG. The numerical and experimental test series are carried out at the Bern University of Applied Sciences, Switzerland REFERENCES [1] European Committee for Standardization (CEN): EN 26801:1991: Joints with mechanical fasteners, Brussels, Belgium, 1991 [2] Kolb J.: Systems in Timber Engineering, Birkhäuser- Verlag, Basel, 2008 [3] Neuhaus, F.H.: Elastizitätszahlen von Fichtenholz in Abhängigkeit der Holzfeuchte, Institut für Konstruktiven Ingenieurbau, Ruhr-Universität Bochum, Technisch wissenschaftliche Mitteilungen Nr. 81-8, Bochum, 1981 [4] Zur Kammer T.: Zum räumlichen Tragverhalten mehrgeschossiger Gebäude in Holztafelbauart, Doctoral thesis, Technische Universität Braunschweig, Germany, 2006

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