English version
Catalog Built on quality, p. 2 Building the future, p. 4 The production cycle, p. 6 Types and layering, p. 14 Structural design, p. 16 Technical specifications, p. 17 The XXL Sistema Integrale, p. 18 Essepi Monoblocco, p. 20 Certifications, p. 24
Design and layout by Paolo Simeone | Photography by Giulio Boem Translation by George Young Printed on Fedrigoni Splendorgel E.W.
I had been working in the windows sector for more than three decades and I had a lot of experience of research and innovation with a market leader in the manufacture of high-tech wooden door and window frames. However, since I was a child, I have always had a passion for construction. For some time I had been nurturing a dream: to invest resources and know-how in modern and sustainable construction, developing smart and eco-friendly building techniques, creating a new benchmark for business synergies. It became clear that the most suitable product for making this dream come true was the solid wood laminate panel and that the best possible raw material, Norway spruce from the Fiemme valley, was staring me right in the face. And so Essepi XXL was created out of the Essepi brand, a cutting-edge company producing X-Lam systems and integrated solutions for all types of building. It is easy to see the future: you just have to follow your dreams. Silvio Pedrotti
Built on quality When innovation, tradition, technology and an eco-friendly approach come together, you get a vision of the future. A vision which was the inspiration for the Essepi XXL factory, set up in 2012 just outside Cavedine in the verdant Valle dei Laghi, part of the Trentino province of northern Italy, with a production line that ensures that the processes are performed with the highest possible levels of efficiency, safety and quality. The plant provides a large operating area, in an environment with controlled temperature and humidity levels, and a manufacturing process which can produce structural X-Lam panels made exclusively to measure and tailored to meet all design requirements. The machinery, from those used for creating joints to those used for planing and calibration, has been conceived, designed and developed internally, as part of an automated production and quality control system which is unique in the industry. The X-Lam panels produced by Essepi XXL do not have any “standard” sizes. Thanks to highly accurate calibration and a special technique for bonding the individual layers, the panels are only manufactured on the basis of the customer’s requirements, which significantly reduces the amount of off-cuts generated and makes the best possible use of the available raw materials. The strength of the Essepi brand is its Sistema Integrale, which brings together the technology and design of Essepi Finestre and the construction methods of Essepi XXL, applying a revolutionary model of production synergies which can be used to build large and spacious buildings with incredibly versatile design possibilities. The state-of-the-art X-Lam and Monoblocco manufacturing techniques, developed using Essepi’s wealth of expertise, dramatically reduce production times and costs for a building, as well as offering considerable advantages in terms of site safety and the urban and environmental impact. As well as its work in Italy, Essepi XXL has to date also put its innovative designs into practice on projects in Austria, Germany and Switzerland.
Essepi headquarters. Cavedine, Trento.
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Building the future The Essepi XXL panel is a wooden structural product made from alternating crosswise bonded layers of lamellas (X-Lam), using timber planks which are classified according to their mechanical strength, as per standard EN 14081. The longitudinal layers are alternated with transverse ones where the grain is laid at right angles to the previous layer, in order to ensure complete dimensional stability, thanks to the way the movements in the wood are compensated in different directions. The first factor which makes Essepi XXL X-Lam panels stand out is the raw material. Essepi XXL only uses wood from forests which have a sustainable management certification (e.g. PEFC, FSC), favouring locally sourced materials drawn from forests in the Trentino and Alto-Adige provinces in the far north of Italy.
Assembly of a pre-fabricated module.
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Every step in the production process, from the raw timber to the finished panel and the integrated systems are designed and planned to achieve the best possible quality, using a variety of technological solutions as required. In particular, the planing and calibration system (which uses mechanical equipment designed and developed by the Essepi team) and the special bonding process, along with the raw materials and the production processes, give the final product a clear performance advantage over normal X-Lam panels. Thanks to the highly accurate operating tools and a fully automated production cycle, Essepi XXL can also offer extremely quick production times and constant process and quality controls at every stage. Versatile, solid, environmentally-friendly, suitable for any type of building: the Essepi XXL panel is the construction component of the future, drawing on centuries of history and tradition.
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The production cycle The Essepi XXL facility stands on a 9,000 m² site, around 4,000 m² of which is indoors. The buildings have a class A energy rating, the highest possible energy performance. The plant comprises three large halls which are fitted with a system to measure the temperature and relative humidity of the air, along with heating and humidification equipment, controlled by sensors located close to the main production equipment. The excellent insulation ensures a constant internal temperature of between 20 and 26 °C.
The wood storage warehouse is fitted with a humidification system to ensure the humidity of the air is stable and controlled at between 50 and 55%. The incoming planks – classified, selected and subject to individual quality controls – are kept in the warehouse for at least seven days in order to stabilise and harmonise with the temperature and humidity conditions in the facility. In the jointing and splicing zone the equipment, set up with the utmost precision, joins the planks together using structural finger joints to create the lamellas. The cutting of the teeth and the bonding operations to join the lamellas are designed to ensure the longest possible lifespan for the product.
Warehouse for storing planks of certified Norway spruce.
Machine used to produce the lamellas.
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Precision planing and calibration system.
The raw lamellas are then automatically taken to the precision planing and calibration machine, which controls their thickness and width according to the final values specified for the piece being processed. Unlike other manufacturers of X-Lam panels, which seek to create smooth surfaces (which are not the most effective for the adherence of the adhesive), Essepi XXL’s special production process includes a calibration stage after planing which can, in a single phase, create either a completely flat surface with a thickness tolerance of less than 5 hundredths of a millimetre, or a rough surface which increases the bonding area by more than 50%, thereby optimising the adherence of the adhesive during the subsequent pressing phase. This increases the bonding strength by more than 50%, providing very high levels of strength and durability for the finished panels. Neither the lamellas nor the layers undergo preservative treatments before the panel is bonded together.
Special calibration machine.
The assembly, bonding and pressing zone also boasts a fully automated production line. It begins with the formation of the individual layers, both longitudinal and transverse, using two dedicated single-layer presses. The layers formed using this method are then lifted and transported to the bonding bench to be inserted into a panel and bonded according to the specific production plan for that panel.
Single-layer longitudinal and transverse press.
Essepi XXL uses single-component polyurethane adhesives free from formaldehydes which, once hardened, are chemically inert. The special method for bonding the layers is also tested for shear strength and delamination in accredited testing laboratories, using a precise quality assurance cycle as set out by the Finnish research centre and certification body VTT. Final bonding line.
The layers are bonded using an automated machine which distributes the adhesive. The panels are compressed using a cold, high-pressure press. The same machine is used to ensure that each panel is completely flat when it leaves the press. From the transfer bench, the panel is then lifted using a gantry crane and transferred to the storage area for unfinished panels, pending processing in the cutting centre.
Bonding process.
A special feature of Essepi XXL’s whole production process is the formation of layers, and thus the creation of panels, of any size. Indeed, Essepi XXL has a production system which was conceived and laid out solely for the production of on-demand layering and made-tomeasure panels, minimising waste from processing and therefore making best possible use of the raw materials. A deliberate financial and environmental decision which drives the entire production cycle and determines the design and operation of the machinery. This is a feature of the company, one which makes Essepi XXL a customerfocussed company, dedicated to the particular structural requirements of the customer’s construction projects, whether residential, commercial or civil.
Movement of the layers.
The large press.
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In the cutting centre the panels are trimmed and crosscut using a 10-axis numerical controlled machine, according to the dimensions ordered and the design requirements of the building. Essepi XXL’s design office can draw up, on request, the full implementation plan for the building, including calculations, plans, cutting lists and site assembly plans.
Arrival of the panel at the cutting centre.
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N°Prod.: Commessa: Cliente: Tipologia: Dimensioni: Peso: Data e ora
08/07/16
268 - 42 2016 - 711 Opendot CLW S7-190
posizione edile
190 x 6400 x 2240 1226 Kg Operatore
Roberto
DTP
512
Silvio Pedrotti
0809-CPD-0766
ETA-12/0362
Cutting centre.
Every single part is labelled with a panel code and is CE marked, providing a unique identifier and traceability through all of the production phases, also ensuring that they are compliant with structural use in buildings.
Finished panels, labelled and ready for despatch.
Processing using CNC cutting machine.
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General view of the warehouse and assembly centre.
From the cutting centre, the labelled panels are stored in the finished products warehouse before being moved by gantry crane onto the load bed of the delivery vehicle.
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Next door to the cutting centre, the XXL Sistema Integrale assembly and pre-fabrication centre is designed to produce walls or whole living modules made from X-Lam, including Essepi Windows doors and windows and accessories. The windows are inserted into the Essepi XXL panel by milling the solid panel itself. As a result the fitting phase does not require the use of secondary frames, whilst the quality of the fit between panel and window has been certified in terms of airtightness and waterproofing by tests carried out at the Ivalsa Trees and Timber Institute from the National Research Council of Italy. The solidity of the factory-fitted coupling between wall and window is very strong and provides solutions for any type of building. The way in which the structural components are assembled means that, once they are loaded onto road transport, they can be delivered straight to the site and fitted straight away, providing significant time and cost savings and an end result which is outstanding both technically and in terms of the construction details.
XXL panels ready for despatch.
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Types and layering WALL PANEL / 3 LAYERS Name
Layers
A (1)
I (1)
W (1)
t
l
t
mm
kN/m2
cm2
cm4
cm3
Composition
Thickness Weight
CLW P3-60
3
20
20
20
60
0.30
600
1800
600
CLW P3-80
3
30
20
30
80
0.40
800
4267
1067
CLW P3-90
3
30
30
30
90
0.45
900
6075
1350
CLW P3-100
3
35
30
35
100
0.50
1000
8333
1667
WALL PANEL / 4 LAYERS Name
A (1)
I (1)
W (1)
l
t
t
l
mm
kN/m2
cm2
cm4
cm3
Layers
Thickness Weight
Composition
CLW P4-100
4
20
30
30
20
100
0.50
1000
8333
1667
CLW P4-110
4
20
35
35
20
110
0.55
1100
11092
2017
WALL PANEL / 5 LAYERS Name
A (1)
I (1)
W (1)
t
l
t
l
t
mm
kN/m2
cm2
cm4
cm3
Layers
Thickness Weight
Composition
CLW P5-100
5
20
20
20
20
20
100
0.50
1000
8333
1667
CLW P5-120
5
24
24
24
24
24
120
0.60
1200
14400
2400
CLW P5-130
5
30
20
30
20
30
130
0.60
1200
14400
2400
CLW P5-145
5
35
20
35
20
35
145
0.73
1450
25405
3504
All of the different types of Essepi XXL panels are always available and are made to measure according to the order received. The maximum production dimensions are 3,150mm (width) and 12,750mm (length) with a thickness of up to 300mm. T = Transverse layers L = Longitudinal layers Weight = Self weight A (1) = Solid cross-section area A (2) = Effective cross-section area I (1) = Moment of inertia with solid cross-section I (2) = Moment of inertia with effective cross-section W (1) = Section modulus with solid cross-section W (2) = Section modulus with effective cross-section E.I. = Effective bending stiffness
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FLOOR PANEL / 3 LAYERS Name
Layers
Thickness
A (2)
I (2)
W (2)
E.I.
l
t
l
mm
cm2
cm4
cm3
N/mm2
Composition
CLW S3-60
3
20
20
20
60
400
1733
578
2.08E+11
CLW S3-80
3
30
20
30
80
600
4200
1050
5.04E+11
CLW S3-90
3
30
30
30
90
600
5850
1300
7.02E+11
CLW S3-100
3
35
30
35
100
700
8108
1622
9.73E+11
FLOOR PANEL / 5 LAYERS Name
Thickness
A (2)
I (2)
W (2)
E.I.
l
t
l
t
l
mm
cm2
cm4
cm3
N/mm2
Layers
Composition
CLW S5-100
5
20
20
20
20
20
100
600
6600
1320
7.92E+11
CLW S5-120
5
24
24
24
24
24
120
720
11405
1901
1.37E+12
CLW S5-130
5
30
20
30
20
30
130
900
15675
2412
1.88E+12
CLW S5-145
5
35
20
35
20
35
145
1050
22247
3069
2.64E+12
CLW S5-150
5
30
30
30
30
30
150
900
22275
2970
2.65E+12
CLW S5-160
5
30
35
30
35
30
160
900
26025
3253
3.12E+12
CLW S5-175
5
35
35
35
35
35
175
1050
35372
4043
4.24E+12
Thickness
A (2)
I (2)
W (2)
E.I.
l
l
t
l
t
l
l
mm
cm2
cm4
cm3
N/mm2
FLOOR PANEL / 7 LAYERS Name
Layers
Composition
CLW S7-190
7
30
30
20
30
20
30
30
190
1500
54525
5739
6.54E+12
CLW S7-210
7
30
30
30
30
30
30
30
210
1500
71325
6793
8.56E+12
CLW S7-220
7
30
30
35
30
35
30
30
220
1500
80625
7330
9.68E+12
CLW S7-245
7
35
35
35
35
35
35
35
245
1750
113261
9246
1.36E+13
Thickness
A (2)
I (2)
W (2)
E.I.
l
l
t
l
t
l
t
l
l
mm
cm2
cm4
cm3
N/mm2
FLOOR PANEL / 9 LAYERS Name
Layers
Composition
CLW S9-270
9
30
30
30
30
30
30
30
30
30
270
1800
141975
10517
1.70E+13
CLW S9-300
9
35
35
30
35
30
35
30
35
35
300
2100
199200
13280
2.39E+13
Structural Design DESIGN CRITERIA XXL PANELS FOR FLOORS AND ROOFS Permanent load
1
1.5
2
2.5
3
Single span (m) 4.5 5 5.5
Imposed load qK
3
3.5
4
1.5
90
100
120
130
145
2
90
100
130
145
2.5
90
120
130
3
90
120
4
100
5
6
6.5
7
175
190
190
210
160
175
190
190
210
145
175
190
190
210
220
130
145
175
190
190
210
245
130
145
175
190
190
210
245
245
120
130
160
175
190
210
220
245
270
1.5
90
100
130
145
160
175
190
190
210
2
90
120
130
145
175
190
190
210
220
2.5
90
120
130
145
175
190
190
210
245
3
100
120
145
160
175
190
210
220
245
4
100
130
145
175
190
190
220
245
270
5
120
145
160
190
190
210
245
245
270
1.5
90
120
130
145
175
190
190
210
245
2
90
120
130
145
175
190
190
210
245
2.5
100
120
145
160
175
190
210
220
245
3
100
130
145
175
190
190
210
245
245
4
120
130
160
175
190
210
220
245
270
5
120
145
175
190
190
210
245
270
300
1.5
100
120
145
160
175
190
210
220
245
2
100
130
145
160
190
190
210
220
245
2.5
100
130
145
175
190
190
210
245
245
3
100
130
145
175
190
190
220
245
270
4
120
145
160
190
190
210
245
245
270
5
130
145
175
190
190
220
245
270
300
1.5
100
130
145
175
190
190
210
245
245
2
100
130
145
175
190
190
210
245
270
2.5
100
130
145
175
190
210
220
245
270
3
120
130
160
175
190
210
220
245
270
4
120
145
175
190
190
210
245
270
300
5
130
145
175
190
210
220
245
270
300
kmod=0.8; kdef=0.6; ɣm=1.45 Service class: 1 Instantaneous deformation limit: L/400 Final deformation limit: L/300 Self weight of XXL panel already included 16
Technical specifications ESSENTIAL REQUIREMENTS
CLASS/USE CATEGORY/VALUE
TECHNICAL SPECIFICATION
Mechanical strength Average Modulus of elasticity parallel to grain E0,mean
12000 N/mm2
Typical Modulus of elasticity parallel to grain Ek,0,05
9500 N/mm2
Bending strength fm.k
24 N/mm2
Compressive strength parallel to grain fc,0,k
24 N/mm2
Compressive strength perpendicular to grain fc,90,k
2.7 N/mm2
Tensile strength parallel to grain ft,0,k
16.5 N/mm2
Tensile strength perpendicular to grain ft,90,k
0.4 N/mm2
Shear strength fv,k
2.7 N/mm2
Shear strength “rolling shear” fR,k
variable, according to arrangement of panels, as per ETA-12/0362
Average Modulus of elasticity perpendicular to grain E90,mean
370 N/mm2
Average Modulus of shearing parallel to grain G0,mean
690 N/mm2
Statement VTT-S-02814-15
ETA-12/0362
Gluing Adhesives compliant with EN 301 or EN 15425 and ETAG 011. Polyurethane-based adhesives Durability Use only in service classes 1 or 2, EN 1995-1-2 Reaction to fire D-s2, d0 (except for floorings). Dfi-s1 (floorings) Fire resistance Charring rate compliant with EN 1995-1-2 : β0=0.65 mm/min; βn=0.7 mm/min Dangerous substances Formaldehyde emissions class E1 as per EN 13986 Other properties Compliant with ETA-12/0362 Air permeability Tests conducted by Cnr-Ivalsa Tress and Timber Institute laboratories in accordance with EN 12114:2011
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The XXL Sistema Integrale The system has been developed by bringing together the research by Essepi Finestre into the technology and design of door and window frames and the construction methods formulated and tested by Essepi XXL. Of these, the advanced X-Lam pre-fabrication technique (which has been designed and developed in full using Essepi’s expertise in this sector) means that whole walls fitted with windows can be assembled in the factory. And not just individual walls: the same goes for entire housing units and a variety of rooms and their on-site installation. The insertion of Essepi Finestre doors and windows in the X-Lam walls without the use of sub-frames, providing a seal between the fittings and panels which is much more accurate than can be achieved on site, ensures the highest possible levels of precision and efficiency and makes them completely airtight, waterproof and windproof. Assembly of a pre-fabricated module.
Fitting of an Essepi Ventura Evo9 window.
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The additional option to manufacture pre-assembled modules in the factory, including partition panels and windows, helps to slash site erection and working times and provides significant safety and environmental impact benefits. An ideal solution, not just for single-family residential buildings, but particularly for multi-storey buildings for commercial or industrial use or in the public and service sector. A genuine first in Italian construction, destined to radically change construction techniques and become the benchmark for the future of a responsible and sustainable industry.
Pre-fabricated module ready for delivery to site.
Positioning of a module. Mayer student hall of residence, Trento.
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Essepi Monoblocco The most recent example of the company’s research and technological innovation is called Monoblocco. This is an integrated wall-and-window solution, fully factoryfitted, ready to be delivered to construction sites. The core of Essepi Monoblocco is an X-Lam panel which acts as a “window hole”, together with an Essepi Finestre window frame. The Monoblocco unit is equipped with the necessary technical and structural components for fitting into the Essepi XXL Sistema Integrale, using sliding guide runners. A full range of fixtures, fittings and accessories such as internal and external reveals, windowsills and shutters and blinds, all fully customisable, are fitted and assembled in the factory as well, using advanced prefabrication techniques.
Essepi Monoblocco: taking Essepi’s technological research into the field. It comprises an X-Lam supporting structure, a window, internal frame, mosquito net, blind or roller shutter, alarm sensors and beams, motors and external frame: one item housing all the technology of an X-Lam panel, a window frame, blinds and security features. Essepi Monoblocco is the most cutting-edge product produced by Essepi, the sum product of business synergies with enormous potential.
Display stand showing a Monoblocco unit in an X-Lam wall.
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Monoblocco unit fitted in an XXL wall. Internal and external views.
The ability to fit the entire Essepi Monoblocco unit on site gives a drastic reduction in costs and completion time, whilst also improving safety and build quality. Once fitted on site, as soon as the shell of the structure has been assembled, and therefore before installing the electrical and hydraulic systems, the blower test can be carried out. Preliminary tests have confirmed that a structure made from X-Lam and fitted with an Essepi Monoblocco unit provides exceptional airtightness values, regardless of the cladding, internal walls or supporting walls used. Monoblocco is made-to-measure, tailored to any project requirements or customer needs, complete with a wide range of models and accessories from Essepi Finestre. It lends itself to use in both civil and private construction with the same strength, durability, energy-efficiency and acoustic performance. The special production method also means that parts can be replaced following final installation without altering the entire structure.
Monoblocco unit (5 m2), weighing 1,000 kg, comprising the X-Lam structure, Vita Evo 9+ window, external surround made from local granite, fully assembled in the factory and installed in a single crane lift.
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Optimisation of costs, sustainability of raw materials, a reduction in the environmental impact of production processes, exceptional durability and security values, rationalisation of logistics, a balance between cost and performance: the integrated design of Essepi XXL, together with technically flawless manufacturing methods, is a technological achievement destined to transform standards of construction, housing and of living.
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Certifications Fsc Essepi only uses wood from forests which have a sustainable management certification and makes every effort to encourage the use of wood from local sources.
CE Marking Essepi XXL panels comply with the essential requirements for sale and use in the European Union, established by the relevant directive, and specified for the full production cycle: from design to manufacture, from release onto the market to the installation of the product, right up to its disposal. Essepi construction products are CE marked in accordance with the Declaration of Performance (DoP) according to the new European Regulation CPR 305/2011.
EOTA Mark Essepi’s technology meets the key requirements of the European Technical Assessment (ETA) for the design and production of the products: mechanical strength and stability; fire safety; hygiene; health and environment; safety of use; noise protection; energy saving and heat retention.
Cnr-Ivalsa Trees and Timber Institute The quality of Essepi XXL panels is checked daily using in house mechanical tests on the bonded joints and delamination tests for production batches carried out by Cnr-Ivalsa. The strict protocols set by Cnr-Ivalsa are used to regularly check and document the resistance class and moisture content of the wood, the temperature and humidity of the atmosphere, the dimensional tolerances, the grammage of the adhesive, the bonding pressures and all of the parameters in the process which affect the quality of the product.
VTT Technical Research Centre of Finland The performance declaration for XXL panels is based on the European technical assessment carried out by the notified certification body VTT in accordance with the procedures specified by EOTA, the European Organisation for Technical Assessment for construction products.
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Contact Essepi XXL Viale De Gasperi, 1/A 38073 Cavedine (TN) T +39 0461.569199 F +39 0461.569141 info@essepi-xxl.it www.essepi-xxl.it www.essepifinestre.it