LokAlp: A Reconfigurable Massive Wood Construction System Based on Off-Cuts from the CLT and GLT Industry

This paper presents LokAlp, a modular timber construction system invented and developed by the authors, inspired by the traditional Blockbau technique, and designed for circularity and self-construction. LokAlp utilizes standardized interlocking blocks fabricated from CLT and GLT off-cuts to optimize material reuse and minimize waste. The study explores the application of massive timber digital materials within an open modular system framework, offering an alternative to the prevailing focus on lightweight structural systems, which predominantly rely on primary engineered wood materials rather than reclaimed by-products. The research evaluates geometric adaptability, production feasibility, and on-site assembly efficiency within a computational design and digital fabrication workflow. The definition of the LokAlp system has gone through several iterations. A full-scale demonstrator constructed using the LokAlp final iteration (Mk. XII) incorporated topological enhancements, increasing connection variety and modular coherence. Comparative analyses of subtractive manufacturing via 6-axis robotic milling versus traditional CNC machining revealed a >45% reduction in cycle times with robotic methods, indicating significant potential for sustainable industrial fabrication; however, validation under operational conditions is still required. Augmented reality-assisted assembly improved accuracy and reduced cognitive load compared to traditional 2D documentation, enhancing construction speed. Overall, LokAlp demonstrates a viable circular and sustainable construction approach combining digital fabrication and modular design, warranting further research to integrate robotic workflows and structural optimization.