Custom Made Box Beams
CREATED TO WRAP EXISTING FRAMING OR TO SAVE WEIGHT
Our skilled crew has perfected the art “disassembling” solid antique timbers and reassembling them into hollow timbers without discernible seams.
Virtually indistinguishable from solid timbers, our custom fabricated box beams are a great choice for customers looking to wrap existing framing or want the look of solid timbers without the weight. Due to the labor and waste involved in manufacturing, box beams are typically more expensive than solid beams. They are typically the best option for applications that require the wrapping of exposed structural elements such as glu-lams, steel I-beams, and steel columns. They can also be used as an alternative to solid beams in applications precluding the use of the heavier solid beams.
We can fabricate them to match the appearance of any of our solid beams or planking options. Although we have made box beams in a continuous run over 40′ long and 24″ tall, there are situations where the material is not available in the requested height or lengths requested.
HAND HEWN BARN TIMBER BOX BEAMS
This is our most popular box beam appearance. To achieve this look, we carefully dissect solid hardwood beams that were originally squared up by hand over 150 years ago and put them back together in a manner that is virtually undetectable upon inspection. Original notches and mortises are filled. These take the most amount of care, effort, and saw blades so they typically run a bit more than our other box beam appearances. Box beam dimensions can typically be provided up to 9″x9″ and up to 35′ without a seam. Larger dimensions can be achieved by gluing up pieces side by side to yield a taller or wider box beam. Thickness is typically 1.25″ or greater due to the amount of texture variation in this material. Containing the original hand hewn surface and patina, each box beam will vary slightly in color, texture, and character.
ORIGINAL SAWN BARN TIMBER BOX BEAMS
To achieve this look, we carefully dissect solid hardwood beams that were originally rough sawn over 150 years ago and put them back together in a manner that is virtually undetectable upon inspection. Original notches and mortises are filled. These take a considerable amount of care, effort, and saw blades so they typically run a bit more than our other box beam appearances. Box beam dimensions can typically be provided up to 9″x9″ and up to 25′ without a seam. Larger dimensions can be achieved by gluing up pieces side by side to yield a taller or wider box beam. Containing the original rough sawn surface and patina, each box beam will vary slightly in color, texture, and character.
HAND HEWN DOUGLAS FIR BOX BEAMS
This is our most versatile option and can be supplied in large volumes. Using the same hand tools as our forefathers, we apply a hand hewn surface on our reclaimed Douglas Fir Box Beams. Because this process removes any patina or paint, it reveals raw wood that is typically stained after installation. After hand hewing the material, we pass it through our sander to remove loose splinters and give the material a polished feel that is ready for waxing. We sell a colored wax that is typically applied on interior beams to enhance the color and texture of this material. Because the wax is a soft finish and easily scratched, it is better to apply it after the beams are installed. For this reason our hand hewn Douglas Fir box beams are provided unfinished. Sizes can be provided typically up to 18″ x 18″ and up to 40′ long. Larger dimensions can be achieved by sawing up solid timbers or gluing up pieces side by side to yield a taller or wider box beam. Box beam sides are typically provided in approx. 1.5″ thick. Being distressed by hand, each box beam will vary slightly in texture and character although these are generally considered pretty consistent when supplied in volume.
ORIGINAL ROUGH SAWN DOUGLAS FIR BOX BEAMS
This is one of the more economical options for our box beams when suitable materials exist. Sizes can be produced up to 14″ x 14″ and lengths up to 30′ on occasion. Larger dimensions can be achieved by gluing up pieces side by side to yield a taller or wider box beam. For customers looking to create these box beams themselves, we can provide the pieces to be cut and assembled on site. Depending on the size and length, most box beams in this appearance are produced at 3/4″ – 1-1/2″ thickness. Containing the original rough sawn surface and patina, each box beam will vary slightly in color, texture, and character.
ORIGINAL SMOOTH DOUGLAS FIR BOX BEAMS
This is one of the more economical options for our box beams when suitable materials exist. Sizes can be produced up to 14″ x 14″ and lengths up to 30′ on occasion. Larger dimensions can be achieved by gluing up pieces side by side to yield a taller or wider box beam. For customers looking to create these box beams themselves, we can provide the pieces to be cut and assembled on site. Depending on the size and length, most box beams in this appearance are produced at 3/4″ – 1-1/2″ thickness. Containing the original smooth surface and patina, each box beam will vary slightly in color, texture, and character.
RECLAIMED “DRIFTWOOD” BOX BEAMS
Our driftwood box beams are made with our driftwood planking. These are a very popular option for those looking for a weathered wood beam appearance in a neutral gray/golden tone. Sizes can be supplied up to 10″ x 10″ and up to 15.5′ long. Larger dimensions can be achieved by gluing up pieces side by side to yield a taller or wider box beam. For those looking to cut and fabricate box beams in this appearance on site, individual boards can be supplied. Containing the original rough sawn surface and patina, each box beam will vary slightly in color, texture, and character.
GRAY BOARD BOX BEAMS
Our gray board box beams are made with our gray board planking. These are a very popular option for those looking for a weathered wood beam appearance in a gray/silver tone. Sizes can be supplied up to 10″ x 10″ and up to 15.5′ long. Larger dimensions can be achieved by gluing up pieces side by side to yield a taller or wider box beam. For those looking to cut and fabricate box beams in this appearance on site, individual boards can be supplied. Containing the original rough sawn surface and patina, each box beam will vary slightly in color, texture, and character.
RECLAIMED REDWOOD BOX BEAMS
Our reclaimed Redwood box beams can be supplied in multiple appearances from clean and contemporary to rough and rustic. Hand hewn, resawn, and surfaced textures are most common in Redwood box beams. Our reclaimed Redwood is some of the finest old-growth material we’ve ever seen. Ultra-tight grain, all-heart and typically free of knots. Sizes can be produced up to 15″ x 15″ x 20′. Please specify texture preference with inquiry.
WHITE OAK BOX BEAMS
This is our most limited box beam offering and not always available. When available, our reclaimed White Oak box beams can be supplied in multiple appearances from clean and contemporary to rough and rustic. Hand hewn, resawn, and surfaced textures are most common in White Oak box beams. Please specify texture preference with inquiry.
