Production Process for Laminated Logs

 Step #1: The Timber:  We work with only “Standing Green” timber.  Each order we run is job specific.  We place the order for the timber required to complete the home at the time of order.  This insures we can control the fungal stains and sun checking that occur in cut timber that has not been kiln dried and conditioned.  Blue stain {sapwood stain} and brown stain are virtually eliminated.

Step#2:  Drying:  We kiln dry the timber in dry kilns designed and built by us specifically for large softwood timber planks.  Prior to placing the timber in the dry kiln, we use data provided by the US Government & the “Forest Products Laboratory” to determine the equalized moisture content of wood at the “destination building” site.  We will dry the material to a point below this.  This insures that there will be no moisture related movement of the wood after delivery.  This step sets us apart from all other manufacturers.  Our drying process virtually eliminates checking and shrinking of the log.  We maintain the timber in the kiln at 150 {deg F} for a minimum of 21 days. 

Step#3:  Wood Processing:  The kiln dries timber planks are processed into precision S4S planks.  Each timber is inspected for defects and appearance.  Some timber cannot be dried to the required moisture content.  These timbers are rejected for use in the log.  Our timber planks are precision milled in kits for the next step, lamination.  All timber used in the lamination lot is machined at the same time to insure consistent thickness.  The surface of the timber prior to laminating is straight and flat.  Our tooling maintains a consistent flatness to within 0.001 inch.  This insures a perfect glue line and consistent glue line thickness.

Step#4:  Laminating:  We laminate our logs in production glue jigs specifically designed for our logs.  These jigs provide a perfectly straight and sold frame to hold the timbers true during the high pressure clamp and cure cycle.  The glue {resin} we use for laminating exceeds the US government’s most stringent requirement for laminating timber.  “ASTM” 2559.  We use an “MF” resin.  It is a two part, thermal-set adhesive.   The glue is applied to each timber using a metering applicator designed and built specifically for our logs.  We insure a consistent glue film thickness and a 100% coverage rate on the timbers.  When cured, the resin is totally inert and approved for exterior structural bonding for softwoods in a wet use environment.  This allows us to offer mixed species logs.  An example would be Cedar exterior for the home and a Pine interior.  This resin is neutral in color so there is not the apparent glue line common to others using the older PRF resins.  Our most commonly requested log is our insulated log.  It is built to the same process as our full timber laminated log but we use a high density (2 lb) EPS core.  The log is built as a box beam and the insulation is fully encapsulated in timber.  When required by the homes design, we can provide structurally engineered logs that fully meet all building codes nationally.  A typical application for this is as a garage door header or bay window header.  These logs while engineered for load retain the same appearance as the timber log.  This eliminates the need to use visible “Glu-Lams” or other structural composite materials.

Step#5:  Profiling:  The completed laminated log needs to be shaped to the desired profile.  This decision was made prior to laminating the logs.  Each lamination design is specific to the desired customer profile.  We offer Square log, D-log, DD-log, and Full round options.

Step#6:  Cutting & Notching:  There are many options to choose from when designing a log home.  The log size, the log profile, the timber species, and the corner configurations need to be determined.  We work with the home owner and the builder early in the design process to insure these wants are delivered.  Typically, our logs are delivered to the job site fully precut and ready for erection.  Window and door openings are provided.  Required cutting on site is minimal.