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Support Beams Laminated Wood vs. Steel I-Beam Prepared for John and Jane Doe by Student P. Scholar May 4, 2015

Table of Contents Table of Figures .............................................................................................................................. iii Glossary of Terms ........................................................................................................................... iv Executive Summary ......................................................................................................................... v Introduction ...................................................................................................................................... 1 Overview .......................................................................................................................................... 2 Options ............................................................................................................................................. 2 Steel I-Beam ................................................................................................................................. 2 Microllam LVL ............................................................................................................................ 3 Criteria ............................................................................................................................................. 3 Total Cost ..................................................................................................................................... 3 Strength ........................................................................................................................................ 3 Aesthetics ..................................................................................................................................... 3 Installation .................................................................................................................................... 3 Comparison ...................................................................................................................................... 4 Strength ........................................................................................................................................ 4 Aesthetics ..................................................................................................................................... 4 Installation .................................................................................................................................... 5 Price ............................................................................................................................................. 5 Recommendation ............................................................................................................................. 6 References ........................................................................................................................................ 7 Graphics References ........................................................................................................................ 8

Table of Figure Figure 1: I beam section dimensions ............................................................................................... 2 Figure 2: Close up view of an LVL beam section, showing the veneer layers ................................ 3 Figure 3: A previously completed project, which included a Microllam beam supported by 2 foot knee-walls and decorative support posts ......................................................................................... 4 Figure 4: installation of a Microllam beam ..................................................................................... 5 Figure 5: Wood blocks attached to a steel I-beam before wallboard installation ............................ 5 Y Table 1: Criteria Analysis ................................................................................................................ 6

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Glossary of Terms Load-bearing wall - A load-bearing wall is a wall that carries the weight (load) of parts of a structure above it, such as the roof load, or the weight of another story above. The load-bearing wall translates this load to the building’s foundation, and therefore must rest on another load- bearing point of the building or on the foundation itself. Exterior sidewalls of a home are typically load-bearing walls [1]. Building code - The set of building regulations which set the standard for building in a specific region. These codes must be upheld by the builder to ensure the safety of the home, and must be verified by a safety inspector before a project can be completed. Dimensional lumber - Any wooden building product that is specified by the American Softwood Lumber Standards sizing system, such as a 2x4, 2x6, 2x8, 4x4, etc... Note that these products are actually specified at slightly smaller dimensions than their names, i.e.) a “2x4” actually measures 1.5 inches by 3.5 inches [2]. Wallboard - Any product used for the base of a finished wall surface, such as drywall, blueboard, or sheetrock. Veneer - A thin slice of wood that is either cut or peeled from a log, and is commonly used in covering furniture products, or can be glued together to make other building products like plywood or structural beams [3]. Live Load – A live load is the load imposed on a structure by moving or movable objects, which can include people, furniture, and external forces from changing weather conditions [4]. Cross-section – The cross-section of a beam is the shape that is seen from the end of the beam, if looking straight at the face of a sliced section. This would be a rectangle for a rectangular beam, or an “I” shape for an I-beam.

Executive Summary My clients wish to remove a 19 foot section of the exterior wall of their home in order to add an additional room. They must choose a building material to be used for a beam which will support the existing structure after the wall is gone. I am comparing a steel I beam with a laminated veneer beam for the remodeling project. Caution must be exercised when modifying the existing structure. The design must be carefully engineered to properly support the building and conform to building codes. The best option will be cost effective, aesthetically pleasing and structurally sound. A main goal of the project is to create a continuous, wide open living space that appears to be seamless and original to the home. Using traditional dimensional lumber is not a practical option here, since this would require a support column in the center of the span in order to be structurally sound. This would create a “broken up” feel, which is not desirable in the finished room. A steel beam would be stronger than any wood based product, and would have a shorter height dimension than its veneer counterpart when considering a beam that spans the whole 19 foot space. This would make for a beam that does not have as much of a visual impact to the completed room. It would not require any additional support within the span, and would not bounce or deflect under load. However, it is the heaviest of the options, and would require additional equipment, manpower, labor and hardware for installation. When finishing the beam with wallboard, wood blocks or specialized metal clips must first be attached to the beam as a base for attaching it. It would also require the use of steel posts wit1h bearing plates to support it. Finally, this will be the most expensive material of the options, with a price of $539 in materials alone. Microllam LVL (laminated veneer lumber) comes in multiple sizes, all engineered to have consistent strength properties. A Microllam beam is stronger and more uniform than equivalent size dimensional lumber. If exposed to leaks or excess moisture, it would not rot or rust like plain lumber or steel because it has a wax coating, and is nonmetallic. It is a much cheaper option than steel, at $368 in materials. It is also easy to finish and blend into the room because wallboard products can be nailed directly to it. A Microllam beam with a cross-section of 1.5 inches by 11 7/8 inches would not require support in the middle of the span as with traditional lumber, but would require columns or partial wall support at its ends when used for a large opening. It will require 4 thicknesses of LVL nailed together, but it is much easier to install than steel since it can be built up one piece at a time. All things considered, I recommend a Laminated Veneer beam as the best option for the project because of its low cost, ease of installation, smooth seamless look and good performance while minimizing the overall cost of the project.

Introduction Today, homeowners have two choices when they have outgrown their current home: relocate or remodel. There are unique advantages and disadvantages to both options. My client has decided that due to their evolving family needs, they will choose to remodel their current home to better suit their needs. The decision to remodel is a growing preference among today’s homeowners. Remodeling a current home is cheaper and offers the homeowners a more stable, familiar and customizable option than purchasing a new home. On March 18, my proposal was approved to perform a study of support beams, and determine which type will be the most effective choice for the remodeling project of my client. I have chosen a steel I-beam and a laminated veneer beam as the best options to compare because they are two of the sturdiest and most commonly used materials for structural support. These options are good for this project because they can be used over long spans with no center support, unlike traditional dimensional lumber products. The goal of the remodeling project is to create a new, wide open living space. By using one of these support beams this goal can be obtained efficiently. I have researched the benefits and possible drawbacks associated with each of the options, and will present my findings along with my recommendation for the most effective option to use as the project begins and moves forward. The report will include an overview of the remodeling project and the importance of selecting the right beam, an explanation of the two options, the criteria for comparing them, the in-depth comparison highlighting the pros and cons of choosing each option, and my personal recommendation for the most effective beam option.

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Overview This is the beginning of a major remodeling project that will give a whole new look and feel to the room, and provide a larger, more practical living space. While this process can be fun and exciting, it is important to consider the process involved with making these changes to the structure of the home. The plan for this project is to remove a 20 foot section of the exterior wall of the house to expand the room into a new space. This wall is a load bearing wall which directly supports the second story and roof structure. When removing a load bearing wall such as this, caution must be exercised to ensure the stability of the home during construction. The load- bearing capacity of the removed wall must then be replaced with a new structural element, which in this case will be a beam. This beam must be designed to be able to reliably support the loads being placed on it for many years, and without deteriorating or causing any part of the home to feel unstable or inferior to its original design. The client does not want their home to feel bouncy, flimsy or cheap. If the wrong decision is made, the home may become bouncy or squeaky, or may feel like low quality workmanship. In a worst case scenario, an incorrectly designed or constructed beam may also cause unsafe or unstable conditions and create a hazard to the home and its occupants. The budget involved in such a project is also of the utmost concern. The client wants to attain their goal of creating more living space in their home with high quality workmanship at a competitive price. The building contractor must be able to provide this quality product while still being able to make a profit. The overall cost of the building materials, along with the labor required to complete the work plays a crucial role in the outcome of the project for both parties. Ideally, you want this beam to perform all of these functions while blending into the new space or being completely invisible if possible. There should not be any oddly shaped or visible unfinished materials. If the right decision is made, the new room will look continuous as if it had been that way all along. Options The following are the details of each individual material option. Specifications and dimensions are collected from sizing tables provided in Weyerhaeuser documentation, as well as from communications with a structural engineer at the York John H Myers and Son store. Steel I-Beam A steel I beam is a rolled steel product that has a cross-section which literally resembles the letter I. I beams are specified using the dimensions shown in Figure 1, Where A is the height, B is the flange width, C is flange thickness, and D is web thickness. The recommended I beam section to be used for this span is W12x58, with dimensions of A = 12.25”, B = 10”, C = 5/8” D = 3/8”. Steel I beams can be used to support incredibly heavy loads over relatively long spans. Figure 1: I beam section dimensions

Microllam LVL An LVL or “Laminated Veneer Lumber” beam is a beam made of many thin sheets of wood veneer glued and pressed together to form a very strong, solid composite material [5]. It is very similar to plywood, but much thicker. Figure 2 shows a close up view of the cross section of an LVL beam. There are numerous brand name LVL products, such as Boise Cascade's VersaLam, Georgia-Pacific's GP Lam, and Weyerhaeuser’s Microllam. I will focus on Microllam products for my comparison because data is readily available from my local lumber yard where they are stocked. Criteria The following are the criteria will be used to compare the beam options, and make a recommendation for the remodeling project. Total Cost The cost of a beam goes much further than just a simple price tag number. Multiple factors must be considered, including material cost, delivery fees, installation labor, tool rental and additional building materials required for installation. Strength The material must be strong enough to withstand dynamic loads under all conditions, including harsh weather, snow loads, live loads of building occupants, future remodeling projects such as tile floors etc. and heavy furniture on upper levels of the home. It must also feel sturdy, and must not be flexible enough to cause cracking or shifting of finished walls in other rooms. Aesthetics The completed room transition should look seamless and the beam should be as small as possible to avoid looking awkward or creating a head-bumping hazard. Installation Installation of the beam should be as quick and easy as possible, without long waits for shipping or delivery to the job site. Ideally, it would also require only the tools and manpower of a small crew, and not create possible safety hazards during the install. Figure 2: Close up view of an LVL beam section, showing the veneer layers

Comparison Strength There are two different design choices if choosing an LVL beam. First is a beam built up from four 1 ¾ inch thick LVL beams, having a cross section of 7 inches by 11 7/8 inches can span 15 feet, but will require additional support to reduce the span to this length. This support could be constructed with support posts, or 2 foot sections of wall on each end of the beam. One finished example of this option from a similar project is shown in Figure 3. The other option is a beam with a 7 inch by 16 inch cross section. This configuration would span 19 feet with no extra support, but would be 4 inches taller. This would likely begin to become a possible head-bump hazard, and would not be as aesthetically pleasing as the first option. The best standard steel I beam section that will support this span, with minimal height in mind is 10 inches by 12 1 8 inches. This option requires no extra support to span this distance, and would be the toughest of the options available, and would have very low deflection under load. Aesthetics A Microllam beam is easy to finish and blend into the room since wallboard products can be nailed to it directly. The engineered wood beam with wall supports, in finished form will be about 7 inches by 12 inches when the wallboard is attached and plastered or painted. This is because the board is roughly ½ inch thick, and plaster may add up to an additional 1 8 inch. There will be two thicknesses added to the width, and one to the height, but the beam will also sit flush with the floor joists of the second story, with the wallboard of the ceiling around it. A steel I-beam spanning the full 19 feet will be almost twice as wide when finished, and would be about the same finished height. Figure 3: A previously completed project, which included a Microllam beam supported by 2 foot knee-walls and decorative support posts

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Installation Since the engineered wood beam will be built using two thicknesses of LVL lumber, the installation will be much more manageable, and will only require two workers and basic tools to put in place. Each thickness will weigh about 122 pounds, based on weight per linear foot specifications from TrusJoist Engineered wood products [6]. A pocket will be framed for one end of the beam, and each piece of LVL will be lifted into this pocket on one end, then the other end will be lifted into position, temporarily supported, and nailed using a pneumatic nailer. Then the additional thicknesses will be put into place and nailed into the previous layer. Finally, the beam will be permanently supported at both ends by additional wood framing or posts. The installation process of a Microllam beam is illustrated by Figure 4 below. A steel beam will weigh more than 1000 pounds, and will require much more manpower, and additional equipment such as hydraulic jacks to help lift it into place. When placing it in position, it will need to be fully supported immediately to ensure safety from the risk of dropping the extreme weight. When installing a steel beam, it is required by building code that it be supported by steel posts, which must include bearing plates and must be attached with bolts at top and bottom. When finishing the beam with wallboard products, it will be necessary to attach wood blocks or specialized metal clips to provide a solid base for the new wall, as shown in Figure 5. Price After considering the required beam sections and spans, prices were obtained for the materials. The LVL beam is stocked in standard lengths of 20 feet. Each individual LVL beam is exactly 1.75 inches in width, and will require 4 pieces to build up the required section. One 20 foot, 11 7/8 tall piece will cost $92. Therefore the total material price for this option would be $370 plus a minimal cost for fasteners, and the cost of additional lumber estimated at about $50. The labor cost associated with installation is estimated to be about $380. Figure 4: installation of a Microllam beam Figure 5: Wood blocks attached to a steel I- beam before wallboard installation

The steel beam would be a custom ordered, single piece beam, with a price of $907.36. The additional steel posts and framing are estimated to cost about $140. The installation would require twice the manpower, with an estimated labor cost of about $700. Recommendation Based on the discussion in my comparison, I have determined which option is the best fit for each of the criterion. Table 1 displays my findings by marking the best choice in each category with a black x. This is a simple way to display and visualize my findings. In the total cost category, the LVL beam is the clear choice. All things considered, it will cost less than half of the steel beam after materials and installation. The steel beam excels in strength and performance, and would provide the sturdiest construction with a solid feel and great longevity, but LVL would not be far behind, and should not have any noticeable bounce in the completed project with decorative support posts and knee walls at its ends. LVL easily wins the Installation and aesthetics categories, with considerably easier installation and a minimized, classy look in the room. Considering all of these factors, based on my research and comparison, I recommend the laminated beam as the option best suited for the project goals. I feel that this option will provide the best performance at an affordable price, as well as being simple for the builder to install. By following this recommendation, I feel that the new room will be affordable, aesthetically pleasing, and structurally sound. It should serve the needs of homeowners for generations to come. Table 1: Criteria Analysis

References [1] Carter, T., 2013, "Load Bearing Wall Identification," from http://www.askthebuilder.com/load-bearing-wall-identification/ [2] 2015, "American Softwood Lumber Standard," Voluntary Product Standard PS 20-15, National Institute of Standards and Technology, pp.16-18. [3] 2014, "The Truth About Veneers and Solid Wood Furniture," from http://www.ducharmewriting.com/The%20Truth%20About%20Veneers%20and%20Solid %20Wood%20Furniture.pdf [4] n.d., "Live Loads Explained for Structural Design," from http://www.nishkian.com/live- loads-explained-for-structural-design/ [5] Wallender, L., 2014, "What's Microlam or LVL (Laminated Veneer Lumber)?," from http://homerenovations.about.com/od/toolsbuildingmaterials/a/artmicrolam.htm [6] 2014, "Trus Joist® Beam, Header and Column Specifier's Guide," TJ-9000, Weyerhaeuser NR, Federal Way, WA. State A., 2006, "Wide flange beams." from http://sketchup.engineeringtoolbox.com/astm-a6- american-standard-steel-s-i-beams-c_2.html 2014, "Engineered Lumber Residential Guide," Lit. Item #123040, Georgia-Pacific Wood Products LLC, Atlanta, GA.

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Graphics References Cover Images: http://continentalsteel.com/carbon-steel/structural-steel/ http://www.crossworksme.com/images/2013%20Jobs/Rousselle%20Kitchen/Rousselle28.JPG Figures: http://www.familyhandyman.com/walls/how-to-install-a-loadbearing-beam/view-all http://www.woodbywy.com/trus-joist/microllam-lvl-beams/ http://www.stlpipesupply.com/wp-content/uploads/2010/11/structural1.jpg http://upload.wikimedia.org/wikipedia/commons/4/47/Laminated_Veneer_Lumber.png