Economic Feasibility of Synthetic Fiber Reinforced Laminated Veneer Lumber (LVL)

Use of synthetic materials to reinforce wood has been discussed in numerous research papers dating from the early 1960s. It has been largely unfeasible to implement this material concept for commodity products due to the high cost of fiber reinforcements relative to wood costs. The changing markets, which has been driving up the price of structural lumber, is also characterized by a decline in the price of synthetic fiber reinforcements due to the rapidly expanding markets. The present study was the economics and markets portion of a technical feasibility study on synthetic fiber reinforcement of laminated veneer lumber (LVL). The objective was to ascertain the economic viability of this material concept and identify specific markets for its use. Cursory evaluations of plausible reinforcements were made to determine the lowest cost to mechanical property ratio. An economic evaluation was performed for a manufacturing process which used E-glass fiber, Douglas-fir veneer, and phenol-formaldehyde resin to produce a number of reinforced products were obtained from stress-rated lumber and LVL on commodity markets. Uses identified included axial and flexural reinforcement of members as well as fastener, splice, or other stress concentration areas. Least costly of the reinforcements to provide tensile strength was an E-glass/phenol-formaldehyde composite. Cash flow analyses showed small returns on investment when the material is marketed against commodity stress-rated solid-sawn lumber. Internal rates of return averaged near 100 percent when the reinforced material was analyzed using product prices, and grades established for an LVL product which is currently marketed.

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