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1 |
High quality Eastern White Pine logs are sawn into squares
(or cants) at the sawmill. The cants are stacked on spacers to
allow air to flow through the bundles to naturally cure the wood. |
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2 |
Bundles are submerged into a solution of Timbor®
Borate Log Treatment. This environmentally safe solution protects
against fungus and insect infestation and kills any larvae present in
the cant. |
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3 |
The cants are air-dried for a 60-90 day period. The
Timbor® residue seeps deep into the wood and replaces sap
moisture as the cant dries. This offers long-term protection,
through-and-through. |
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4 |
The cants are then kiln-dried on a 12 to 21-day drying cycle
reducing moisture to 19%, more or less. The wood reaches a
temperature of 160-degrees, which further sterilizes the cants
against any insects or pests that may be present. |
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5 |
The kiln-dried cants are placed in an Acclimation Shed for 30
days. This allows for natural adjustment to atmospheric conditions
and helps stabilize the cants before they are milled and helps
prevent movement of the logs after milling. |
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6 |
The stabilized cants are shaped into the appropriate log
profile using a computer-controlled, precision Molder/Planer.
The pattern is checked for accuracy to 1/32 of an inch. |
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7 |
The shaped logs are moved through the cut-off line and are
individually graded to “Log Wall 40” standards. Our certified log
graders are monitored by the nation's leading independent wood grading
agency, Timber Products Inspection, Inc. |
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8 |
Each log is marked to designate it's position in the log wall per
the blueprints, and the logs are cut to length within 1/8-inch.
All defect is removed, and the Log Wall 40 grade stamp is
applied. The blueprint cut-sheet is marked to show the log has been
manufactured. |
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9 |
Special notches called dado's (dā’-dō) are made where a log's end
will butt against and join another log. The notches will accommodate a
wooden dovetailed spline to seal the joint. |
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10 |
The logs are drilled using 1/2-inch diameter bits with a
1-1/4-inch diameter countersinking head to accommodate 3/8-inch lag
bolts. The holes are drilled on an approximate 32-inch spacing. |
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11 |
Logs are notched with the appropriate corner joinery notch
(saddle notches, dovetails, butt-and-pass). A second blueprint
cut-sheet is marked as a double-check to show the log has been
manufactured. |
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12 |
The log length is double-checked to be accurate within
1/8-inch. |
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13 |
Corner joinery notches are checked against a formed template
for accuracy. The notches are sanded, and splintering is
removed. |
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14 |
End cuts are checked to be perfectly square. The cuts
are sanded, and splintering is removed. |
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15 |
Countersinking is checked for proper depth.
Holes are smoothed, and splintering is removed. |
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16 |
Each log is checked for adherence to Tennessee Log Homes' own
high appearance standards. Manufacturing marks and rough spots are
sanded. |
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17 |
Tongues and Grooves are checked against formed templates
to insure the proper size and spacing. |
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18 |
Logs are randomly stacked to check for proper size, length and overall
fit. |
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19 |
Extra logs are manufactured to further insure the customer will
have what is needed to construct their log wall system. The two
cut-sheets are checked against each other as a triple-check to
insure that all logs have been manufactured. |
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20 |
Logs are bundled according to their position in the log wall
system. Each complete bundle is wrapped with special lumber
wrap. The bundles are banded with plastic banding, and corner
protectors are used over the wrap. |
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21 |
Each bundle is labeled with the date, the customer's name, and the
bundle contents. Completed bundles are stored together in the dry
with other bundles from the same log wall system until time for
shipment. |
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22 |
Bundles are loaded for shipment on three-inch wooden spacers
to accommodate a forklift. The spacers are attached to the bundles
for easy forklift unloading and transport. The loads are tarped
before shipment in nearly all instances. |
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23 |
A certificate copy of this checklist is signed by each
responsible Quality Assurance person as each step is performed. The
certificate will be provided to you when your home is shipped. |
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24 |
Once your logs are assembled and all necessary tasks are
performed, your Lifetime Limited Warranty will be activated. |
