XLAM has delivered manufacturing solutions for large timber structures, demonstrating a step-change in the scale and precision achievable through advanced mass timber fabrication to achieve long clear-span timber structures.
This was achieved through a fully integrated Design for Manufacture and Assembly (DfMA) approach, where structural design, fabrication, logistics and erection methodology were resolved as a single coordinated system.
The structural solution has been integrated in recent applications including a 97m clear span structure comprising large-scale arched trusses rising 35.6m with curved Laminated Veneer Lumber (LVL) chords with XLAM-manufactured Cross Laminated Timber (CLT) webs and purlins. LVL enabled complex curvature and high bending performance, while CLT provided diaphragm action, dimensional stability and weight efficiency.
1. Technologies Unique to Timber
Execution relied on advanced timber-specific modelling and fabrication systems. CADWORK was enhanced with custom Python APIs, enabling automated validation and precision control across complex geometries.
A fully coordinated BIM workflow resolved connection detailing, fabrication sequencing and erection methodology prior to manufacture, reducing risk across thousands of interfaces.
CNC machining to tolerances of 0.1mm ensured precise alignment of curved members and complex joints.
Quality assurance was embedded throughout production. Each billet was graded, moisture-validated and laboratory-tested (MOR, MOE, delamination), with full traceability to forest origin. Multi-axis pressing systems ensured consistent adhesive performance at scale.
2. Innovations Only Recently Feasible
Recent advancements in parametric modelling, API-driven automation and digital QA systems enabled this level of complexity.
Custom checking tools embedded within the modelling workflow allowed real-time validation of geometry and connections, significantly reducing coordination risk.
Direct integration between digital models and fabrication extended to laser-cut steel interfaces, enabling millimetre-accurate timber-to-steel coordination and controlled structural behaviour during installation.
3. Uniquely Viable in Timber
Timber’s high strength-to-weight ratio and suitability for prefabrication were critical to delivery at this scale.
The structure, representing the largest clear-span timber application in the Southern Hemisphere to date, was manufactured as transportable elements for long-distance logistics using specialist trailers. Prefabrication reduced onsite time, minimised waste and enabled just-in-time installation.
The benefits of using timber resulted in reduced self-weight which lowered foundation demand, while precision manufacturing enabled large spans with fewer components.
Conclusion
This demonstrates how digitally enabled manufacturing, precision fabrication and timber-specific innovation can redefine structural scale.
XLAM has established a new benchmark for mass timber capability—proving that large, free-spanning structures can be efficiently realised through advanced, integrated manufacturing systems.
