Survey of Irish Timber Frame Manufacturers
Survey of Irish Timber Frame Manufacturers
2004
compiled by Peter Wilson
PA G E
Table of Contents Executive Summary
2
1.
Introduction
3
1.1 1.2 1.3 1.4 1.5 1.6
3 3 3 5 5 7
2.
3.
4.
Objective The Wood Marketing Federation Irish Timber Frame Manufacturers’ Association Timber Frame Housing 2002 Consortium Study Irish House Construction Overview Historic Supply Chain
Methodology
9
2.1 Timber Frame Manufacturers Identification 2.2 Questionnaire Development 2.2.1 Calls and Interviews
9 9 10
Results
11
3.1 Timber Specifications and Sourcing 3.1.1 Studs 3.1.2 Floor Joists 3.1.3 Battens 3.1.4 Bracing and Water Tank Supports 3.1.5 Traditional Cut Roofs 3.1.6 Roof Trusses 3.2 Timber and Wood Product Suppliers 3.2.1 Specialised Timber Agents 3.2.2 Direct from Scandinavia 3.2.3 Builders’ Merchants 3.2.4 Irish Sawmills 3.2.5 Board Materials 3.3 Statistical Analysis 3.3.1 Sawn Timber Usage 3.3.2 House Type 3.3.3 Perception/ Experience of suppliers of sawnwood 3.3.4 Quality Schemes 3.3.5 General Company Information 3.4 General Comments
11 11 11 11 12 12 12 12 12 13 13 13 13 14 14 14 16 17 17 17
Conclusions
18
4.1 Quality & On-Site Erection 4.2 Alternative Materials 4.3 Promotion 4.4 Sawn Timber and Timber Frame Manufacturing 4.4.1 Irish Sawnwood
18 18 18 19 20
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Survey of Irish Timber Frame Manufacturers 2004
Executive Summary For the last eleven years there has been year on year growth in the house construction sector. House completions in 2004 reached almost 77,000 units which exceeded many estimations. The switch to timber frame construction in new buildings is dramatic, from 5% in the mid-nineties to approximately 25% in 2004, representing over 19,000 units. Forecasts by some industry commentators suggest that timber frame construction will account for 50% of new build houses within five to seven years. In Scotland the proportion of timber frame in new house construction is already at 60%. Given house completions for 2004 of 77,000 units, the potential sawnwood consumption in the timber frame housing sector is in the region of 160,000m3 with an additional estimated 15,000m3 used for truss rafters. About 50% of the sawn timber is used in studding with the balance used in flooring joists, bracing, battens and in-fills. An indication of growth in this sector is the fact that the National Standards Authority of Ireland (NSAI) currently administers a quality scheme to forty-six Timber Frame Manufacturing Companies, with twenty further applications pending. The supply chain for wood products to the timber frame sector is varied. Typically material is sourced directly, through timber agents or via the builders’ merchant. All respondents are operating factory quality control schemes monitored by NSAI. While the majority of timber frame construction is finished to a high standard, a number of interviewees expressed concern that a serious threat to the integrity of timber frame buildings lies in the area of on-site workmanship and control. To address this issue the NSAI and FÁS have set up a FETAC training course for Timber Frame Erectors and the NSAI will have a new registration scheme for timber frame erectors coming out in 2005. The future for timber frame construction looks very bright. Its development has already brought changes to traditional supply chains and will bring more in the near future. This report is intended to create an awareness of the timber frame industry’s needs and the support required from manufacturers and suppliers to this construction sector.
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1.
Introduction
1.1 Objective The objective of this timber frame manufacturers’ survey, undertaken by the Wood Marketing Federation, is to increase the understanding of the timber frame construction sector and of the wood product utilisation market. The purpose is to establish the procurement dynamics for wood products, the type and level of service given and the potential for increasing the use of wood products in this sector. 1.2 The Wood Marketing Federation The Wood Marketing Federation (WMF) was founded in 1989 and comprised all the major organisations involved in the forestry and forest products industry at that time. Its main objectives are to promote the use of wood as a versatile, viable and renewable resource for the building and building related industries and to ensure that the highest standards and highest quality are maintained. The WMF carried out a number of wood promotion campaigns and initiated a major project to publish a timber specifier’s guide because information and guidance on timber for specifiers was not available to the same extent as other materials such as concrete, steel and plastic. The outcome “Woodspec - A Guide to Designing, Detailing and Specifying Timber in Ireland” was published in June, 2001 and was widely circulated to third level colleges, media, designers, wood processors, architects, engineers and other specifiers. During 2003, Woodspec was promoted through a series of road shows in Waterford, Wexford, Galway, Limerick and Dublin which were sponsored by the Wood Marketing Federation. Part of the strategy of the WMF is to gain a better understanding of the wood products market and to initiate market studies to provide members with market sector information, hence this study of the timber frame construction sector. 1.3 Irish Timber Frame Manufacturers’ Association The Irish Timber Frame Manufacturers’ Association (ITFMA) is the Trade Association for the timber frame manufacturing industry supplying to the island of Ireland. The ITMFA was formed in 1991 in recognition of a quickly growing industry. It now has a full time working office from where all administration and events are co-ordinated. Its main objective is the development of an industry offering a quality product which offers end users complete satisfaction. This is achieved through information exchange, publicity and promotion, quality standards, procedures and practices, and adoption of new technology and methods as appropriate. Currently the ITMFA has twenty four members all of whom are quality accredited through a recognised body - National Standards Authority of Ireland’s Timber
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Survey of Irish Timber Frame Manufacturers 2004
Frame Manufacturing Scheme or the UKTFA Manufacturers’ Scheme. The Association has its own guide to practice and membership criteria beyond the presentation of a technical quality approval mark. The member companies account for more than 85% of ex-factory turnover in the sector. ITFMA members have supplied domestic dwellings and public service buildings predominantly to the Irish market but also to a limited export market, for longer than 30 years, currently producing in excess of 16,000 units between them annually. A significant rise in production has occurred since the beginning of this decade and this rise is set to increase further. It is anticipated that output is likely to account for more than half of new homes in the next 5 years. The industry employs approximately 800 people full time, in manufacturing and erection, and supports the employment of hundreds more in component and services supply and in site preparation. The Association aims to be the representative voice for the growing Irish timber frame industry.
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1.4 Timber Frame Housing 2002 Consortium Study A consortium of consultants was commissioned by the Department of Environment, Heritage and Local Government to study construction of residential buildings using timber frame construction methods in Ireland in 2002. The terms of reference for the study were; to examine practice and procedure in timber frame construction in both the private and local authority housing sectors; to assess current regulations and technical requirements on timber frame housing and to assess systems pertaining to quality control within the timber frame construction industry. It is recommended that all interested parties should become familiar with this document. 1.5 Irish House Construction Overview Since the mid 1990’s housing in Ireland has been increasing annually (Figure 1) and now Ireland has one of the highest rate of completion per head of population in any country in Europe (Figure 2).
80000 70000 60000 50000 40000 30000 20000 10000
2004
2003
2002
2001
2000
1999
1998
1997
1996
1995
0
Figure 1: Irish House Completion 1995-2004. Source: Department of the Environment, 2005.
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Survey of Irish Timber Frame Manufacturers 2004
Republic of Ireland Northern Ireland Great Britain Germany Sweden 0
5
10
15
20
Figure 2: Number of houses built per 1000 population in various European countries in 2004. Source: CSO, 2005.
However, with the increase in housing activity, there has been a shift in the type of house being built from the traditional bungalow and detached house to the semi-detached house and apartment (Figure 3) which, by the nature of their construction, use less sawnwood.
40000 35000 30000
1996 2000
25000
2004
20000 15000 10000 5000
Bungalow
House Detached
Figure 3: Source:
S U R V E Y
House Semi-D
House Terrace
Flat / Apartment
Total
0
Irish House Completion 1996, 2000 and 2004 by house type. CSO, 2005.
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The number of new build houses and apartments in Ireland using timber frame construction has risen dramatically over the past five years (Figure 4). Informed sources predicted a 25% market share in 2004 (NSAI, 2004). This was achieved with over 19,000 units built in 2004. Market share could grow to 50% or more in the course of the next five to seven years. The growth in market share has resulted in a change in the traditional timber supply chain from forest through to completed buildings.
25% 20% 15% 10% 5%
Figure 4: Source:
Source:
2004
2001
2000
1998
Percentage of housing unit completions using timber frame construction. ITFMA, 2004.
Country / Region
Table 1:
1996
1994
1992
1990
0%
% Timber Frame of New House Completions
Scandanavia
90%
USA
80%
Canada
90%
Scotland
60%
Australia
60%
New Zealand
75%
Ireland
22%
Percentage of housing unit completion using timber frame construction in various countries in 2003. ITFMA, 2003.
1.6 Historic Supply Chain Until the late 1990’s, processed construction timber from sawmills both in Ireland and overseas was marketed to the construction industry through builders
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Survey of Irish Timber Frame Manufacturers 2004
merchants. The principal groups are Chadwick’s, Heiton Buckley, Brooks, McMahon and Associated Hardware, all with multi-branch outlets. A host of smaller independent merchants throughout the country also sell timber to the construction industry. As there is little standardisation in the traditional housing sector, the builders’ merchants must hold extensive sawn timber stocks in order to meet customer demand. At the same time, they are pressurised to operate on a JIT basis. Forecasting the demand for specific sizes is difficult and this feeds back to the sawmills both in Ireland and Scandinavia. Economists predict that the housing sector will contract within the next two years. Builders’ merchants are concerned that growth in timber frame construction combined with this inevitable house construction drop will seriously reduce their market share as there is likely to be less demand for sawnwood products through the traditional channels. One of the advantages of timber frame construction is the use of standardised sawn timber components. This study aims to identify the standard timber components used and the approximate volumes of these going into this market. The Wood Marketing Federation, following discussions with other industry players, were aware of the trends outlined and took a decision to initiate a survey of a number of key timber frame manufacturers to determine the impact on the timber market of this changing situation. Mr. Peter Wilson of Resource Management was appointed to carry out a number of confidential face to face interviews in the timber frame manufacturing sector and compile a report on the findings of the survey.
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O F
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2.
Methodology
2.1 Timber Frame Manufacturers Identification Currently there are forty timber frame manufacturers registered, and twenty applications that are being processed, with National Standard Authority of Ireland (NSAI) in their quality scheme. Following discussions with Mr. Bill Robinson, formerly of Enterprise Ireland and currently contracted to them on technical issues, and Mr. Bob Davis of NSAI, twenty timber frame manufacturers were identified as potential interviewees for the survey. These included all the major manufacturers as well as a number of smaller operators. One manufacturer in Northern Ireland was interviewed. The companies were written to by the WMF Chairman advising them about the survey and the agreement of the ITMFA was also received. 2.2 Questionnaire Development A nine page questionnaire was compiled by Peter Wilson of Resource Management. The initial drafts were discussed with: External • Bob Davis (NSAI); •
Bill Robinson (formerly of Enterprise Ireland); and
•
Lorna Kelly (Irish Timber Frame Manufacturers Association).
Wood • • • • •
Marketing Federation Gerard Murphy – Chairperson; Donal Magner - Secretary; Sean Wiley - (Enterprise Ireland); Eugene Hendrick - (COFORD); and Richard Lowe – Coillte.
The topics covered in the questionnaire were: • Company Details; • Production Data; • Sawnwood Products Used; • Timber Specifications; • Perceptions / Experience of different source countries; • Board Products used; and • Promotion (of wood).
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Survey of Irish Timber Frame Manufacturers 2004
It was decided not to circulate the questionnaire prior to the interview. The questionnaire was designed as an attempt to form a picture of the industry, its future trends, and the impact of these trends on roundwood and wood product suppliers. Participants were assured of complete confidentiality. 2.2.1 Calls and Interviews Contact names within each company had been provided by the ITFMA and each was telephoned or emailed to arrange an interview.
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
2004
compiled by Peter Wilson
PA G E
Table of Contents Executive Summary
2
1.
Introduction
3
1.1 1.2 1.3 1.4 1.5 1.6
3 3 3 5 5 7
2.
3.
4.
Objective The Wood Marketing Federation Irish Timber Frame Manufacturers’ Association Timber Frame Housing 2002 Consortium Study Irish House Construction Overview Historic Supply Chain
Methodology
9
2.1 Timber Frame Manufacturers Identification 2.2 Questionnaire Development 2.2.1 Calls and Interviews
9 9 10
Results
11
3.1 Timber Specifications and Sourcing 3.1.1 Studs 3.1.2 Floor Joists 3.1.3 Battens 3.1.4 Bracing and Water Tank Supports 3.1.5 Traditional Cut Roofs 3.1.6 Roof Trusses 3.2 Timber and Wood Product Suppliers 3.2.1 Specialised Timber Agents 3.2.2 Direct from Scandinavia 3.2.3 Builders’ Merchants 3.2.4 Irish Sawmills 3.2.5 Board Materials 3.3 Statistical Analysis 3.3.1 Sawn Timber Usage 3.3.2 House Type 3.3.3 Perception/ Experience of suppliers of sawnwood 3.3.4 Quality Schemes 3.3.5 General Company Information 3.4 General Comments
11 11 11 11 12 12 12 12 12 13 13 13 13 14 14 14 16 17 17 17
Conclusions
18
4.1 Quality & On-Site Erection 4.2 Alternative Materials 4.3 Promotion 4.4 Sawn Timber and Timber Frame Manufacturing 4.4.1 Irish Sawnwood
18 18 18 19 20
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
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Survey of Irish Timber Frame Manufacturers 2004
Executive Summary For the last eleven years there has been year on year growth in the house construction sector. House completions in 2004 reached almost 77,000 units which exceeded many estimations. The switch to timber frame construction in new buildings is dramatic, from 5% in the mid-nineties to approximately 25% in 2004, representing over 19,000 units. Forecasts by some industry commentators suggest that timber frame construction will account for 50% of new build houses within five to seven years. In Scotland the proportion of timber frame in new house construction is already at 60%. Given house completions for 2004 of 77,000 units, the potential sawnwood consumption in the timber frame housing sector is in the region of 160,000m3 with an additional estimated 15,000m3 used for truss rafters. About 50% of the sawn timber is used in studding with the balance used in flooring joists, bracing, battens and in-fills. An indication of growth in this sector is the fact that the National Standards Authority of Ireland (NSAI) currently administers a quality scheme to forty-six Timber Frame Manufacturing Companies, with twenty further applications pending. The supply chain for wood products to the timber frame sector is varied. Typically material is sourced directly, through timber agents or via the builders’ merchant. All respondents are operating factory quality control schemes monitored by NSAI. While the majority of timber frame construction is finished to a high standard, a number of interviewees expressed concern that a serious threat to the integrity of timber frame buildings lies in the area of on-site workmanship and control. To address this issue the NSAI and FÁS have set up a FETAC training course for Timber Frame Erectors and the NSAI will have a new registration scheme for timber frame erectors coming out in 2005. The future for timber frame construction looks very bright. Its development has already brought changes to traditional supply chains and will bring more in the near future. This report is intended to create an awareness of the timber frame industry’s needs and the support required from manufacturers and suppliers to this construction sector.
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
PA G E
1.
Introduction
1.1 Objective The objective of this timber frame manufacturers’ survey, undertaken by the Wood Marketing Federation, is to increase the understanding of the timber frame construction sector and of the wood product utilisation market. The purpose is to establish the procurement dynamics for wood products, the type and level of service given and the potential for increasing the use of wood products in this sector. 1.2 The Wood Marketing Federation The Wood Marketing Federation (WMF) was founded in 1989 and comprised all the major organisations involved in the forestry and forest products industry at that time. Its main objectives are to promote the use of wood as a versatile, viable and renewable resource for the building and building related industries and to ensure that the highest standards and highest quality are maintained. The WMF carried out a number of wood promotion campaigns and initiated a major project to publish a timber specifier’s guide because information and guidance on timber for specifiers was not available to the same extent as other materials such as concrete, steel and plastic. The outcome “Woodspec - A Guide to Designing, Detailing and Specifying Timber in Ireland” was published in June, 2001 and was widely circulated to third level colleges, media, designers, wood processors, architects, engineers and other specifiers. During 2003, Woodspec was promoted through a series of road shows in Waterford, Wexford, Galway, Limerick and Dublin which were sponsored by the Wood Marketing Federation. Part of the strategy of the WMF is to gain a better understanding of the wood products market and to initiate market studies to provide members with market sector information, hence this study of the timber frame construction sector. 1.3 Irish Timber Frame Manufacturers’ Association The Irish Timber Frame Manufacturers’ Association (ITFMA) is the Trade Association for the timber frame manufacturing industry supplying to the island of Ireland. The ITMFA was formed in 1991 in recognition of a quickly growing industry. It now has a full time working office from where all administration and events are co-ordinated. Its main objective is the development of an industry offering a quality product which offers end users complete satisfaction. This is achieved through information exchange, publicity and promotion, quality standards, procedures and practices, and adoption of new technology and methods as appropriate. Currently the ITMFA has twenty four members all of whom are quality accredited through a recognised body - National Standards Authority of Ireland’s Timber
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
3
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Survey of Irish Timber Frame Manufacturers 2004
Frame Manufacturing Scheme or the UKTFA Manufacturers’ Scheme. The Association has its own guide to practice and membership criteria beyond the presentation of a technical quality approval mark. The member companies account for more than 85% of ex-factory turnover in the sector. ITFMA members have supplied domestic dwellings and public service buildings predominantly to the Irish market but also to a limited export market, for longer than 30 years, currently producing in excess of 16,000 units between them annually. A significant rise in production has occurred since the beginning of this decade and this rise is set to increase further. It is anticipated that output is likely to account for more than half of new homes in the next 5 years. The industry employs approximately 800 people full time, in manufacturing and erection, and supports the employment of hundreds more in component and services supply and in site preparation. The Association aims to be the representative voice for the growing Irish timber frame industry.
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
PA G E
1.4 Timber Frame Housing 2002 Consortium Study A consortium of consultants was commissioned by the Department of Environment, Heritage and Local Government to study construction of residential buildings using timber frame construction methods in Ireland in 2002. The terms of reference for the study were; to examine practice and procedure in timber frame construction in both the private and local authority housing sectors; to assess current regulations and technical requirements on timber frame housing and to assess systems pertaining to quality control within the timber frame construction industry. It is recommended that all interested parties should become familiar with this document. 1.5 Irish House Construction Overview Since the mid 1990’s housing in Ireland has been increasing annually (Figure 1) and now Ireland has one of the highest rate of completion per head of population in any country in Europe (Figure 2).
80000 70000 60000 50000 40000 30000 20000 10000
2004
2003
2002
2001
2000
1999
1998
1997
1996
1995
0
Figure 1: Irish House Completion 1995-2004. Source: Department of the Environment, 2005.
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
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Survey of Irish Timber Frame Manufacturers 2004
Republic of Ireland Northern Ireland Great Britain Germany Sweden 0
5
10
15
20
Figure 2: Number of houses built per 1000 population in various European countries in 2004. Source: CSO, 2005.
However, with the increase in housing activity, there has been a shift in the type of house being built from the traditional bungalow and detached house to the semi-detached house and apartment (Figure 3) which, by the nature of their construction, use less sawnwood.
40000 35000 30000
1996 2000
25000
2004
20000 15000 10000 5000
Bungalow
House Detached
Figure 3: Source:
S U R V E Y
House Semi-D
House Terrace
Flat / Apartment
Total
0
Irish House Completion 1996, 2000 and 2004 by house type. CSO, 2005.
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
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The number of new build houses and apartments in Ireland using timber frame construction has risen dramatically over the past five years (Figure 4). Informed sources predicted a 25% market share in 2004 (NSAI, 2004). This was achieved with over 19,000 units built in 2004. Market share could grow to 50% or more in the course of the next five to seven years. The growth in market share has resulted in a change in the traditional timber supply chain from forest through to completed buildings.
25% 20% 15% 10% 5%
Figure 4: Source:
Source:
2004
2001
2000
1998
Percentage of housing unit completions using timber frame construction. ITFMA, 2004.
Country / Region
Table 1:
1996
1994
1992
1990
0%
% Timber Frame of New House Completions
Scandanavia
90%
USA
80%
Canada
90%
Scotland
60%
Australia
60%
New Zealand
75%
Ireland
22%
Percentage of housing unit completion using timber frame construction in various countries in 2003. ITFMA, 2003.
1.6 Historic Supply Chain Until the late 1990’s, processed construction timber from sawmills both in Ireland and overseas was marketed to the construction industry through builders
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
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Survey of Irish Timber Frame Manufacturers 2004
merchants. The principal groups are Chadwick’s, Heiton Buckley, Brooks, McMahon and Associated Hardware, all with multi-branch outlets. A host of smaller independent merchants throughout the country also sell timber to the construction industry. As there is little standardisation in the traditional housing sector, the builders’ merchants must hold extensive sawn timber stocks in order to meet customer demand. At the same time, they are pressurised to operate on a JIT basis. Forecasting the demand for specific sizes is difficult and this feeds back to the sawmills both in Ireland and Scandinavia. Economists predict that the housing sector will contract within the next two years. Builders’ merchants are concerned that growth in timber frame construction combined with this inevitable house construction drop will seriously reduce their market share as there is likely to be less demand for sawnwood products through the traditional channels. One of the advantages of timber frame construction is the use of standardised sawn timber components. This study aims to identify the standard timber components used and the approximate volumes of these going into this market. The Wood Marketing Federation, following discussions with other industry players, were aware of the trends outlined and took a decision to initiate a survey of a number of key timber frame manufacturers to determine the impact on the timber market of this changing situation. Mr. Peter Wilson of Resource Management was appointed to carry out a number of confidential face to face interviews in the timber frame manufacturing sector and compile a report on the findings of the survey.
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
PA G E
2.
Methodology
2.1 Timber Frame Manufacturers Identification Currently there are forty timber frame manufacturers registered, and twenty applications that are being processed, with National Standard Authority of Ireland (NSAI) in their quality scheme. Following discussions with Mr. Bill Robinson, formerly of Enterprise Ireland and currently contracted to them on technical issues, and Mr. Bob Davis of NSAI, twenty timber frame manufacturers were identified as potential interviewees for the survey. These included all the major manufacturers as well as a number of smaller operators. One manufacturer in Northern Ireland was interviewed. The companies were written to by the WMF Chairman advising them about the survey and the agreement of the ITMFA was also received. 2.2 Questionnaire Development A nine page questionnaire was compiled by Peter Wilson of Resource Management. The initial drafts were discussed with: External • Bob Davis (NSAI); •
Bill Robinson (formerly of Enterprise Ireland); and
•
Lorna Kelly (Irish Timber Frame Manufacturers Association).
Wood • • • • •
Marketing Federation Gerard Murphy – Chairperson; Donal Magner - Secretary; Sean Wiley - (Enterprise Ireland); Eugene Hendrick - (COFORD); and Richard Lowe – Coillte.
The topics covered in the questionnaire were: • Company Details; • Production Data; • Sawnwood Products Used; • Timber Specifications; • Perceptions / Experience of different source countries; • Board Products used; and • Promotion (of wood).
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
9
PA G E
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Survey of Irish Timber Frame Manufacturers 2004
It was decided not to circulate the questionnaire prior to the interview. The questionnaire was designed as an attempt to form a picture of the industry, its future trends, and the impact of these trends on roundwood and wood product suppliers. Participants were assured of complete confidentiality. 2.2.1 Calls and Interviews Contact names within each company had been provided by the ITFMA and each was telephoned or emailed to arrange an interview.
S U R V E Y
O F
I R I S H
T I M B E R
F R A M E
M A N U F A C T U R E R S
2 0 0 4
