Producing Hardwood Cross-Laminated Timber (HCLT) Mats from Low-Grade Red Oak Lumber

The use of cross-laminated timber (CLT) has significantly grown in North America, but hardwood species have not yet been deemed a viable raw material for manufacturing CLT panels. Therefore, softwood species continue to serve as the only approved material for CLT in structural applications according to ANSI/APA PRG-320. Nonstructural CLT products that utilize low-grade lumber from hardwood species, are a good option for introducing hardwoods into the CLT market. Of the hardwood species located within Appalachia, northern red oak (Quercus rubra) is readily available. The purpose of this research was to develop hardwood cross-laminated timber mats utilizing low-grade red oak lumber. In order to manufacture red oak CLT mats, the best adhesive and bonding parameters had to be identified. Overall, sample CLT panels were made using three adhesives with nine different setups for each adhesive. The sample panels were processed into smaller blocks and separated for cyclic delamination and shear-block tests following the ANSI/APA PRG-320 standards. This research determined that a phenol–resorcinol formaldehyde (PRF) adhesive produced the lowest percentage of delamination, satisfying the delamination requirements. The PRF adhesive also produced the largest percentage of wood failure in shear-block testing, however, the results fell short of meeting the requirements. A Taguchi statistical analysis was used to predict the optimal bonding parameters for each adhesive. The optimized bonding parameters for the polyurethane (PUR) adhesive produced favorable results, indicating the delamination results have the potential to nearly meet the standard requirements, while the predicted shear results would exceed the requirements.