The most dramatic architectural beam-based remodel Artéfice contributed to recently was the renovation of the Genoa Lakes Golf Course. In a $12 million renovation, Owner Mario Antoci transformed the semi-private course into a world class resort. The first objective was to give the existing Plain Jane clubhouse some Old World elegance. Architect Jeffrey Lundahl and Interior Designer Christine Hallen-Berg selected hand-hewn beam boxes to frame the existing architecture. Our craftsmen were able to make these three-sided hollow boxes look like 18-inch thick timbers by hand hewing and then applying a heavy, dark finish coat so no side seams could be detected. The design team repeated the beam theme in all of the new construction at the Sierra Nevada resort before it re-opened in July 2001.

Hand hewn architectural box beams accounted for nearly a quarter of our manufacturing volume in the last five years. Beam boxes are the obvious solution for encasing steel in a ceiling. Given the snow-loads in mountain communities, roofs of large homes need the strength of steel. Then a designer has to find a good way to wrap the steel to create an inviting feeling. The hand hewing is very popular because it lends an air of Old World craftsmanship.

We dry material for the architectural box beams in our kiln prior to manufacturing. In many cases, select structural Douglas fir has the desired look. This material is sold as kiln dried at about 15% moisture content, which is very unstable. We place such material on sticks so the air can flow through the load while in the kiln. It usually takes us roughly ten days to get the moisture content to roughly 8%. The material is fairly stable at 8% and ready for manufacturing.

Solid, structural, exposed beams are growing in popularity too. Large timbers can also be a long-lead item. Timber shipments can also be expedited by working with radio frequency kilns that specialize in large timbers. Typically, timbers can now be dried in around a week. Although the process is costly, timbers can be dried to around 12 percent, which eliminates most of the checking and twisting that occurs after the manufacturing process.

Not only are beams big in terms of popularity, they tend to be the largest wood member going into a home. We once constructed an intricate residential beam that spanned 30 feet. Five craftsmen would be working on it at one time. The volume of a beam package usually inspires a general contractor to seek a beam manufacturer. In most cases, the contractor doesn't have space inside a building shell to build and finish beams. If working outside, they run the risk of having weather destroy their most highly visible interior finish item. I highly recommend building beams in a shop.

Our shop is busy manufacturing beams because they are big - really big.