SBIR-STTR Award

This proposal presents a new and innovative method for converting low grade lumber to quality structural engineered laminated studs (lam-studs). The procedure will dramatically increase the portion of a log that can be used for structural applications requiring high quality wood material. It is estimated that an additional 20% of log material will be upgraded in structural products with this innovative method. The proposed method laminates and then re-saws economy grade 2.x 4" material to produce lam-studs. In this way, flaws in the original lumber are effectively diffused through the material. Preliminary work shows that the resulting product is equal to or better than a similar high quality solid wood stud without flaws. The low grade lumber to be used in the proposed process is obtained from conventional sorting in sawmill operations. In the proposed work, methods will be evaluated and selected for fabricating the lam-studs from low grade lumber. Engineered materials will be produced at Wyoming Sawmills, and used for laboratory strength and materials testing. Analyses will be performed to establish the viability of the product for meeting building code structural requirements. A systems analyses will be performed to establish an optimum sawmill operating process.Applications:Dramatic increases in the fraction of a log that can be used for quality structural materials will result from this innovation. The cost of the engineered material will be competitive with solid high grade structural material. The method is applicable to virtually all sawmills operating in the United States and around the world. Increased utilization of existing wood supply and low grade tree harvest will be enabled by this innovation.

Applications:The Phase II work will demonstrate pilot plant production of LamStud lumber, establish a database to support certification, and demonstrate the utility of the LamStud process for lumber grades higher than stud grade, and sizes larger than 2x4's The LamStud process offers all sawmills the opportunity to significantly lower operating costs by lowering forest raw material requirements, and increasing high grade lumber yield. LamStud production can be implemented at sawmill operations with minimal impact on sawmill operations, and low capital investment requirements. LamStud material construction applications include wall studs, and potentially higher grade uses, such as laminated beams, and larger size lumber.