Embracing the future of sustainable mass timber construction in Australia. By Campbell McInnes

Allied Forest Products has long been a dependable wholesaler in Australia’s timber industry, providing a wide array of quality timber products to timber merchants, resellers, manufacturers, and fabricators. Since its establishment, Allied Forest Products has continually evolved to meet the diverse needs of its customers across the nation. With a legacy of over a century in timber manufacturing, handling and logistics, the company is now setting its sights on the emerging mass timber market in Australia through its newly launched division, Allied Mass Timber. I sat down with brothers, Kieran, and Stephen Chehab to discuss what their motivation was to create the new Allied Mass Timber Division.

 

Above: Kieran Chehab left, and Stephen Chehab right, on the new Allied Mass Timber warehouse location, where single level prototypes can be built.

 

ENTERING THE MASS TIMBER ARENA

“Allied Forest Products have been involved with glulam, since 2012. Chehab, S advised, “we have been selling Hyne Timber, GL Beams from the beginning, however at the same time, we have always had open dialog with a range of overseas producers as well.” Chehab, K added, “the CLT and Mass Timber market in Australia has slowly been building momentum in more recent times, however this is not a new market
for us”.

In explanation to why the new division, Chehab, K explained, “we were motivated by a dual purpose, to set up the new division: to enhance the availability of high- quality mass timber and engineered wood products (EWP) in Australia, and to efficiently manage logistics for building projects in Sydney and around Australia. We believe this strategic move will position Allied Mass Timber at the forefront of an evolving market”.

With over a century of combined knowledge and experience across multiple generations, Allied Forest Products recognized the challenges of balancing timber production and importation with the timing needs of construction sites, as well as the intricacies of the mass timber construction cycle.

Above: The Bond building is a great example of how mass timber enhances the look and feel of a building.

BENEFITS OF USING MASS TIMBER IN CONSTRUCTION

Mass timber construction offers numerous advantages over traditional building methods, making it an increasingly popular choice in the construction industry. Looking at these benefits include:

Environmental Benefits

Mass timber construction is significantly more environmentally friendly than traditional methods:

  • It sequesters carbon, with timber buildings acting as carbon sinks.
  • The production process generates fewer carbon emissions compared to concrete and steel manufacturing.
  • Timber is a renewable resource, with sustainable forestry practices ensuring continuous growth and replanting.

Construction Efficiency

Mass timber construction offers several advantages in terms of efficiency:

  • Faster construction timelines due to prefabrication of components off-site
  • Lighter weight materials can reduce transportation costs
  • Construction time can be reduced, saving time and money.

Structural Performance

Despite being lighter than traditional materials, mass timber exhibits excellent structural properties:

  • High strength-to-weight ratio, allowing it to perform well during seismic activity.
  • Ability to withstand high winds and earthquakes.

Energy Efficiency

Mass timber construction contributes to energy-efficient buildings:

  • Excellent insulation properties and can reduce heating and cooling costs.

As the industry continues to evolve, these advantages are likely to drive increased adoption of mass timber in various building types here in Australia.

Above: Mass timber being used to create multi level buildings, with large end sections.

 

 

 

LOGISTICS: MATERIAL HANDLING AND TIMING

Allied Mass Timber is orchestrating a complex logistics operation to ensure the seamless supply and delivery of high- quality timber.

The complexity of logistics in mass timber construction cannot be understated. Chehab, K explained, “once timber orders are placed with an overseas producer, the production process is set in motion and cannot be halted. He added, “as the timing of deliveries is always a critical issue, Allied Mass Timbers’ newly established standalone warehouse in Ingleburn addresses this challenge head-on, offering the capability to store timber securely until it is required on-site”. With specially designed rigid and semi-trailers and a commitment to minimizing damage during transport, Allied Mass Timber ensures that timber arrives on schedule and in pristine condition.

In most cases, once timber arrives from overseas, there is generally nowhere to store large materials onsite as well as keep them protected from the elements. Due to weather and other out of control issues, delays on large construction sites are somewhat inevitable! This is where Allied Mass Timber can fill the gap.

Damage to the timber is costly and disruptive to the whole construction operation. It is vital that the right people, who have the knowledge and experience are the ones handling timber.

Chehab, S explained, “we are utilising staff we have with over 30 years of timber handling experience. In addition, we have also hired some younger staff members, who are ex-carpenters and are trained and understand how timber can be fragile and needs to be handled. These staff members are experts in their field”.

Chehab, K added, “Allied Mass Timber has job specific machinery for handling the large, long, and sometime unique timber components, for all the various CLT and similar components”.

With the investment that Allied Mass Timber are making, they are gearing up to be able to handle any logistic and or handling opportunity that may present itself. Chehab, S said, “we are already in talks regarding the potential of two additional logistic handling projects and both Kieran and I are excited about this. We would not be able to take on more work if it wasn’t due to the implementation of the right people, machinery, and systems. Allied Mass Timber have been able to pave the way and fill any gaps that exist within the supply cycle”.

 

 

SPECIALISED ROBOTIC HANDLING

Understanding the importance of minimizing the damage at all unloading and loading points, Allied Mass Timber have invested in a robotic machine which has the capability to either load or unload up to 45-feet of a container in one motion. The steel platform that is slid into the bottom of the full container is then mechanically retracted. This process not only allows the unloading of a container without damaging the contents but is also a quicker and much safer way of unloading goods from a 20, 40 or even 45 foot containers.

This process is yet another link in the chain that Allied Mass Timber have closed to minimise any potential risk of damage to the valuable timber cargo.

 

Above: Stephen Chehab, left and Kieran Chehab, right on site to inspect their robotic unloading machine under construction.

 

A LANDMARK CONSTRUCTION PROJECT

Allied Mass Timber were recently approached by a large construction company to discuss the key issues around the construction of erecting mass timber buildings in Australia, this being the logistics issue. Speaking further with this construction company and understanding their issues surrounding the logistics and installation of mass timber around timing and handling of materials, created the perfect opportunity for Allied to put forward their expertise and come up with a practical solution to the logistics for this customer.

Following this meeting, Allied Mass Timber were awarded a contract to work with the local construction company on a world significant mass timber tower project which will be constructed in Sydney. Chehab, K said, “This mass timber structure is at the leading edge of this application with carbon sequestration construction. The building will have a combined focus on wellness, environmental innovation, and overall design excellence to create a Sydney icon”. He added, “this landmark project not only signifies a monumental achievement in sustainable construction but also underscores Allied Forest Products commitment to excellence and innovation in the timber industry”.

From the Allied Mass Timber site, they will not only have the service available to unload, store, and resupply mass timber to constructions sites, undamaged and on time, but can also purchase and supply to customers as well. Allied Mass Timber will be seeking to work with designers and specifiers and other customers to supply and arrange the install also.

Our involvement in this project reflects our capacity to handle large-scale, high-profile ventures while upholding the highest standards of quality and service.

TRAINING AND INNOVATION

At the Allied Mass Timber site, there is a designated area for constructing full-scale building prototypes on a single level. Chehab, K advised, “this setup provides numerous training opportunities. First, it enables the actual assembly of mass timber components. Once a prototype is up, it serves as a training ground for other trades and installers, including electricians, plumbers, glaziers, and flooring teams, focusing on handling and fixings”.

By offering this unique training ground, fosters an opportunity where all skilled trades can gain valuable knowledge, insight and understanding as well as address any unexpected challenges safely and in a controlled environment, potentially accelerating the installation time on site.

 

Above: The prototype at Allied Mass Timber site is used for training many different trades.

 

SCALE AND TIMING

The prototype for this project has been built in the Allied Mass Timber warehouse and training has already been carried out.

The large project that Allied Mass Timber have been gearing up for is about to commence. Chehab, K explained “there will be approximately 16,000 m3 of timber which will equate to 400 odd containers of mass timber and timber glue laminated components of which Allied Mass Timber will be responsible for handling”. The material which has been manufactured in Europe, is due to start arriving in November 2024. Chehab, S added, “our current capabilities would be to handle double this capacity”. This gives them plenty of room for current expansion and additional work.

The project has commenced with the foundation work which is well on its way. The first delivery of mass timber and timber components is not due to be delivered to site until February 2025 and will continue through till the first half of 2026, with the overall construction of the building to be completed in 2027.

Chehab, S explained, “we have already started discussions with this client about other future Australian projects that are currently in the developing stages”.

In addition to the timber and timber components which Allied Mass Timber are charged with storing and delivering, they will also be responsible for delivering some other building materials for this project.

The project involves the construction of a massive timber structure that will set new benchmarks in both scale and sustainability. This state-of-the-art building is designed to harmonize with the environment while showcasing the versatile applications of timber in modern architecture.

 

Above: Mass timber structures can be engineered to be very versatile.

 

HELPING TO SHAPE THE FUTURE

Allied Mass Timber are looking to dominate this space. They want to look at and research every possible option that may give their customers an advantage.

Like many other timber products, builders are constantly on the search for a cheaper option, without reducing the quality or integrity of the overall build. Chehab, S explained “this is no different for mass timber products, where Allied are often asked if there is a cheaper alternative?” He added “Allied Mass Timber have tested their “allBEAM” LVL product and are now able to offer their allBEAM in larger end sections.

Customers can also use these larger allBEAM in mass timber construction projects in Australia”. This is not a new concept as such, as this LVL have already been used in the European market. By using an LVL product for mass timber construction, it can reduce the sizes that are required to be used which not only has the potential for cost savings, but there are also other benefits as well. Due to the testing that has been completed, their allBEAM LVL product can be produced not only in larger end section, but they can produce custom sizes, which would also be suitable for Mass Timber projects including large floor panels.

Allied Mass Timber’s goal is to see more mass timber being used more broadly in Australia, which could include social housing and larger residential projects, with the hope that this product becomes a more mainstream product.

Chehab, S added, “if we can eat into the market share that historically has been dominated by the concrete and steel products and convert some of this market share into using mass timber, we will achieve a biophilic environment, as the benefits of mass timber buildings are not only environmentally positive, but they also benefit people mentally and physically as well”.

Allied Mass Timber wants to be heavily involved with shaping the future for the uses of timber and mass timber construction. Chehab, S concluded, “we are excited to be involved in the Australian mass timber movement and look forward to continuing our legacy of innovation and excellence in the timber industry for generations to come”.

For more, visit www.afp.com.au