Seamless build efficiency in a stunning natural setting

Nestled in a stunning natural setting, the project site presented several challenges. Limited accessibility made transporting and assembling construction materials difficult, requiring innovative solutions to ensure a smooth and efficient build. Additionally, the project called for materials that not only delivered exceptional structural performance but also harmonised aesthetically with the environment.

Red Stag TimberLab’s involvement:

Red Stag TimberLab (RSTL) was engaged to supply and manufacture all structural timber components, including Cross-Laminated Timber (CLT) floors, walls, and roofs, as well as Glue-Laminated Timber (Glulam) beams and columns. Leveraging its expertise, RSTL provided:

• Off-Site manufacturing: Prefabricating the structural timber elements off-site to precise specifications enabled fast and seamless on-site assembly. This approach not only addressed the site’s accessibility challenges but also reduced on-site labour and accelerated construction, ensuring efficient progress from the floor slab to the roof.
• Single-source supply: As a single-source supplier for all structural engineered timber elements, RSTL provided a fully coordinated drawing package, ensuring seamless connection detailing, reduced shop drawing review times, and a streamlined installation process.

Additionally, the lightweight nature of CLT panels and Glulam components minimised crane lifts compared to traditional materials, further enhancing construction efficiency.

Digital fabrication

Every component was meticulously modelled in a 3D digital environment, enabling precision CNC profiling for exact dimensions. This approach not only ensured structural integrity but also minimised installation errors. Connections were pre-integrated with brackets and fixings and delivered as a kitset for a flawless and expedited build process.

Sustainability and renewable energy

The extensive use of CLT and Glulam in the project emphasises a commitment to sustainability. As New Zealand's lowest-carbon CLT supplier, Red Stag TimberLab uses its renewable energy generation to lead in sustainable construction.

• Bio-Fuel energy: Offcuts from sawing and planning generate electricity and thermal energy for drying timber, with surplus electricity exported to the national grid.
• Thermal energy efficiency: Red Stag Timber uses wood waste for kiln drying, reducing CO2 emissions and landfill waste while addressing over 85% of a modern sawmill’s energy needs.

Results

Through innovative off-site manufacturing, digital fabrication, and sustainable practices, RSTL’s involvement transformed a challenging site into a showcase of efficiency and design excellence. The prefabricated structural timber elements enabled a rapid build, minimised on-site disruptions and labour required, and delivered a warm, natural aesthetic that complements the surrounding environment. Combined with the visual appeal of exposed timber surfaces, this project is a testament to the synergy between sustainable practices and design excellence.