Box Beam Fabrication

 

CUSTOM BOX BEAMS

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. We typically seam material together to give it the appearance of stacked timbers when the height is not feasible in a single piece and when the lengths are not available, we recommend steel brackets to wrap the seams in the length to give the appearance of a continuous beam.

Some of our most popular options are shown below. Feel free to ask about a custom box beam order using any of our planking products as well.

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. 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 10″x10″ 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 recommended at 1.25″ or greater due to the amount of texture variation in this material. 

Information needed to produce quote:

Inside Dimensions (if covering existing framing)

Number of Sides 

Outside Dimensions (Width x  Height x Length)

Quantity (Pricing is discounted in volume)

HAND HEWN DOUGLAS FIR BOX BEAMS

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.

Information needed to produce quote:

Inside Dimensions (if covering existing framing)

Number of Sides 

Outside Dimensions (Width x  Height x Length)

Quantity (Pricing is discounted in volume)

SANDED DOUGLAS FIR BOX BEAMS

We typically produce our “Sanded Douglas Fir Box Beams” from our reclaimed Douglas fir planking – making it one of the more economical options for our box beams. Sizes can typically be produced up to 14″ x 14″ and lengths up to 30′. 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″ thickness.

Information needed to produce quote:

Inside Dimensions (if covering existing framing)

Number of Sides 

Outside Dimensions (Width x  Height x Length)

Quantity (Pricing is discounted in volume)

GROUND FINISH DOUGLAS FIR BOX BEAMS

The “Ground” finish we apply to our reclaimed Douglas fir box beams is achieved with a series of sanders to give a more polished and worn appearance than our sanded Douglas fir box beams shown above. Sizes can typically be produced up to 14″ x 14″ and lengths up to 30′. 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, sanded (Ground) and assembled on site. Depending on the size and length, most box beams in this appearance are produced at 3/4″ thickness.

Information needed to produce quote:

Inside Dimensions (if covering existing framing)

Number of Sides 

Outside Dimensions (Width x  Height x Length)

Quantity (Pricing is discounted in volume)

RECLAIMED “DRIFTWOOD” BOX BEAMS

Our driftwood box beams are made with out 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. Most box beams in this appearance can be made with 3/4″ thick sides. For those looking to cut and fabricate box beams in this appearance on site, individual boards can be supplied.

Information needed to produce quote:

Inside Dimensions (if covering existing framing)

Number of Sides 

Outside Dimensions (Width x  Height x Length)

Quantity (Pricing is discounted in volume)

GRAY BOARD BOX BEAMS

Our Gray Board box beams are made with out weathered gray 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. Most box beams in this appearance can be made with 3/4″ thick sides. For those looking to cut and fabricate box beams in this appearance on site, individual boards can be supplied.

Information needed to produce quote:

Inside Dimensions (if covering existing framing)

Number of Sides 

Outside Dimensions (Width x  Height x Length)

Quantity (Pricing is discounted in volume)

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 16″ x 16″ x 20′. The box beam thickness will depend on sizing and appearance and will typically range from 3/4″ to 1.5″.

Information needed to produce quote:

Inside Dimensions (if covering existing framing)

Number of Sides 

Outside Dimensions (Width x  Height x Length)

Quantity (Pricing is discounted in volume)

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