Process Overview
Our six-step process transforms raw reclaimed lumber into premium building materials ready for professional installation. Each step includes multiple quality checkpoints, safety protocols, and environmental controls designed to ensure consistent, high-quality results while minimizing waste and environmental impact at every stage.
The process from sourcing to delivery-ready product typically takes 2 to 6 weeks depending on the material type, required processing, and kiln drying schedule. Rush orders are available for in-stock material that has already completed kiln drying. Custom milling adds 1 to 3 weeks depending on complexity and quantity.
Throughout the process, we maintain full chain-of-custody documentation. Every piece of wood is tracked from its source building through each processing step to the customer's delivery. This traceability is not just a quality assurance measure — it enables the material passport and sustainability certificate that accompany every order.
| Step | What Happens | Duration | Waste Generated |
|---|---|---|---|
| 01 — Sourcing | Site assessment, species identification, material extraction | 1-14 days | Zero |
| 02 — De-Nailing | Metal detection, fastener removal, inspection, grading | 1-3 days | Metal recycled |
| 03 — Drying | Kiln drying, heat treatment, moisture verification | 5-42 days | Zero |
| 04 — Milling | Planing, re-sawing, profiling, dimensional cutting | 1-5 days | 100% reused |
| 05 — QC | Six-point inspection, material passport preparation | 0.5-1 day | Zero |
| 06 — Delivery | Site logistics, careful transport, installation support | 1-5 days | Zero |
Sourcing & Acquisition
We maintain relationships with over 60 demolition crews, renovation contractors, warehouse owners, and municipal agencies across the tri-state area. When a building comes down or a structure is renovated, we evaluate the timber for species, condition, dimensions, and reuse potential. Our sourcing specialists visit an average of 12 to 15 sites per week, evaluating available material and coordinating extraction logistics.
Quality Checkpoints
- On-site species identification by trained specialists using visual, tactile, and tool-based methods
- Structural integrity assessment including load testing for beams and timbers
- Contamination screening for lead-based paint, chemical treatments (CCA, creosote), and pest damage
- Volume estimation and logistics planning for extraction and transport
- Photographic documentation of material in situ for provenance records
- Coordination with demolition schedule to maximize recovery before mechanical demolition begins
- Assessment of material accessibility, rigging requirements, and site safety conditions
- Negotiation of acquisition terms — we pay fair market value for quality reclaimed material
Site Assessment Protocol
Every sourcing opportunity begins with a site visit by one of our trained specialists. They conduct a systematic walk-through of the structure, identifying species, estimating volumes, assessing condition, and flagging any contamination concerns. The assessment typically takes 1 to 3 hours depending on the size and complexity of the structure. The specialist produces a written report with photos, species identification, estimated board footage by species and dimension, condition grades, and a recommended extraction plan.
Deconstruction vs. Post-Demolition Salvage
When possible, we prefer to deconstruct — carefully dismantling the structure to maximize wood recovery and quality. Our deconstruction division, led by Tom Whitfield, uses hand tools, reciprocating saws, and small equipment to disassemble buildings piece by piece. This approach recovers 70 to 85% of available lumber in reusable condition, compared to 15 to 25% recovery from post-demolition sorting. For projects where full deconstruction is not feasible, we coordinate with the demolition contractor to extract high-value timber before mechanical demolition begins.
Equipment
- F-250 and F-350 pickup trucks
- 16-foot flatbed trailer
- Portable metal detectors
- Moisture meters
- Species identification field kit
Time Estimate
Site assessment: 1-3 hours. Material extraction: 1 day to 2 weeks depending on scope.
Safety Protocol
All sourcing staff are OSHA-30 certified. Hard hats, steel-toed boots, high-visibility vests, eye protection, and hearing protection are mandatory on all job sites.
De-Nailing & Inspection
Every piece of reclaimed wood arrives with its history — and usually a lot of nails, screws, staples, and other embedded metal. Our team meticulously removes all fasteners using electromagnetic metal detectors and hand tools. This is painstaking work: a single reclaimed beam can contain dozens of embedded nails, some driven in over a century ago and now rusted flush with the surface. After de-nailing, each board is visually inspected and sorted by species, dimension, and quality grade.
Quality Checkpoints
- Electromagnetic metal detection with industrial-grade Metriguard detectors scanning all six faces
- Manual fastener extraction using nail pullers, end nippers, and pry bars to minimize wood damage
- Deep metal scanning for embedded fragments that surface detection might miss
- Visual grading for defects including checks, splits, rot, insect damage, and staining
- Character assessment for desirable features: patina, nail holes, saw marks, weathering
- Species identification and confirmation using grain pattern, color, weight, and smell
- Dimensional measurement and sorting into standard and non-standard sizes
- Rejection and separation of contaminated or structurally compromised material
Metal Detection Process
Each board passes through our metal detection station where it is scanned on all surfaces using an industrial electromagnetic detector. The detector identifies the location and approximate depth of all metallic objects. Technicians mark each fastener location with chalk and extract them one by one using hand tools selected to minimize damage to the surrounding wood. After extraction, the board is scanned again to confirm complete metal removal. This double-scan protocol is essential because hidden metal can damage milling equipment and poses a safety hazard.
Grading System
We use a proprietary dual grading system developed by our senior wood specialist David Kim. Each piece receives both a structural grade (assessing load-bearing capacity, dimensional stability, and defect impact) and a character grade (assessing aesthetic qualities including patina, grain pattern, color, and distinctive features). This dual system allows us to match material to applications where structural performance matters, applications where aesthetics matter, or applications where both are important.
Equipment
- Metriguard electromagnetic metal detectors
- Industrial nail pullers and end nippers
- Pin and pinless moisture meters
- NHLA grading reference materials
- Digital calipers and measuring tools
Time Estimate
De-nailing: 5-15 minutes per board depending on fastener density. Full inspection: 2-3 minutes per piece.
Safety Protocol
De-nailing technicians wear cut-resistant gloves, safety glasses, and steel-toed boots. Tetanus vaccination is required for all de-nailing staff.
Drying & Treatment
Moisture content is critical for structural performance, dimensional stability, and preventing future issues like warping, checking, and mold growth. We kiln-dry all reclaimed lumber to appropriate moisture levels using our commercial dehumidification kiln. We treat for pest concerns using heat treatment — never chemicals. Our kiln holds up to 5,000 board feet per cycle and operates continuously throughout the year.
Quality Checkpoints
- Kiln drying to 6-8% moisture content for interior applications (flooring, paneling, furniture)
- Kiln drying to 12-15% moisture content for exterior applications (siding, decking, fencing)
- Heat treatment to 160°F+ core temperature for a minimum of 30 minutes for pest elimination (ISPM-15 compliant)
- No chemical treatments — ever — including no pressure treatment, no borax, no fumigation
- Continuous moisture metering throughout the drying cycle with data logging
- Controlled cooling period to prevent surface checking from rapid moisture differential
- Post-kiln equilibration period of 48-72 hours before further processing
- Documentation of moisture content readings at entry, during cycle, and at exit
Kiln Drying Process
Our commercial dehumidification kiln operates at temperatures between 120°F and 170°F with precise humidity control. The drying schedule is adjusted based on species, initial moisture content, thickness, and intended application. Hardwoods like oak and maple require slower, more gradual drying to prevent internal stress and checking — a typical cycle for 4/4 hardwood stock takes 10 to 14 days. Softwoods like pine and fir can be dried more aggressively, with typical cycles of 5 to 7 days for 4/4 stock. Thick timbers (4 inches and above) require extended cycles of 3 to 6 weeks. Moisture content is continuously monitored using embedded probes connected to a digital logging system.
Heat Treatment for Pest Control
All reclaimed lumber undergoes heat treatment to ISPM-15 standards as part of the kiln drying cycle. This requires the core temperature of the wood to reach 160°F (71.1°C) and maintain that temperature for a minimum of 30 minutes. This process eliminates all insects, larvae, and eggs without the use of any chemical treatments. We document the heat treatment process with time-temperature data logs that are available to customers upon request and included in the material passport for every order.
Equipment
- Nyle L200 commercial dehumidification kiln (5,000 BF capacity)
- Delmhorst pin-type moisture meters
- Wagner Orion pinless moisture meters
- Embedded kiln probes with digital data logging
- Infrared thermometer for surface temperature verification
Time Estimate
Kiln drying: 5-42 days depending on species, thickness, and target moisture content. Equilibration: 48-72 hours.
Safety Protocol
Kiln area is restricted to trained operators. Temperature and humidity are monitored remotely. Fire suppression system is installed and tested monthly.
Milling & Processing
Depending on the end use, we can plane, re-saw, joint, rip, profile, sand, or finish reclaimed lumber to virtually any specification. From rough-sawn barn boards to precision-milled tongue-and-groove flooring, our milling facility handles it all. Our milling team, led by James Rodriguez, operates industrial-grade equipment maintained to exacting standards to ensure consistent results and tight tolerances.
Quality Checkpoints
- Planing and surfacing: S1S (surfaced one side), S2S (surfaced two sides), S4S (surfaced four sides)
- Re-sawing for thinner stock, bookmatched panels, or maximizing yield from thick timbers
- Custom profiling: tongue-and-groove, shiplap, bead board, V-groove, channel rustic
- Jointing for straight, true edges on boards intended for glue-ups or panel assembly
- Ripping to specified widths with parallel edges
- Sanding to specified grits (80 through 220) for finish-ready surfaces
- Dimensional cutting to specification with tolerances of ±1/32 inch
- Custom moulding profiles matched from customer samples or architectural drawings
Planing & Surfacing
Our industrial planer removes material in passes of 1/32 to 1/16 inch to reveal the clean wood beneath the weathered surface. Planing reclaimed wood often reveals stunning colors and grain patterns hidden under decades of patina — a dramatic transformation that surprises many first-time buyers. We plane to customer-specified thicknesses with a tolerance of ±1/32 inch. For projects where surface patina is desired, we can skip-plane (light passes that clean the surface while preserving character) or hand-brush to remove loose material without altering the aged appearance.
Re-Sawing
Our industrial bandsaw re-saw can split thick stock into thinner boards — turning a 12/4 beam into multiple 4/4 boards, for example. This is particularly valuable for maximizing yield from rare species like American chestnut or for creating bookmatched panels where two consecutive slices from the same piece create a mirror-image grain pattern. Re-sawing is also used to produce veneer-thickness stock (1/8 to 1/4 inch) for specialized applications.
Custom Profiling
Our moulder can produce a wide range of profiles including tongue-and-groove (in multiple dimensions), shiplap, bead board, V-groove, channel rustic, and custom moulding profiles. We can match existing profiles from customer samples — a common need for renovation and restoration projects where new material must integrate seamlessly with existing historic woodwork. Profile setup time is typically 1 to 2 hours; production runs vary based on quantity and complexity.
Equipment
- Powermatic 24-inch industrial planer
- Wood-Mizer LT40 wide bandsaw re-saw
- Weinig Rondamat moulder/profiler
- 12-inch industrial jointer
- Sliding table saw with 14-foot capacity
- Wide-belt sander (36-inch capacity)
Time Estimate
Planing: 100-200 BF per hour. Re-sawing: 50-100 BF per hour. Custom profiling: 75-150 LF per hour depending on profile complexity.
Safety Protocol
All milling operators wear hearing protection, safety glasses, and dust masks. Dust collection system runs continuously during all milling operations. Emergency stop controls are within arm's reach at every station.
Quality Control
Before any product leaves our facility, it undergoes a comprehensive final quality check. We verify dimensions, moisture content, grade, surface quality, and overall condition against the customer's specifications. We also prepare and include a material passport that traces the wood back to its source, documenting the full chain of custody from salvage to delivery.
Quality Checkpoints
- Dimensional accuracy verification against order specifications (tolerance: ±1/32 inch)
- Final moisture content reading with both pin-type and pinless meters
- Grade confirmation per our dual structural/character grading system
- Surface quality inspection: checking for mill marks, tear-out, snipe, and other defects
- Profile verification for tongue-and-groove, shiplap, and custom profiles using gauges
- Quantity verification: board count, linear footage, and board footage calculation
- Material passport preparation with species, source, processing details, and moisture data
- Sustainability certificate preparation documenting estimated carbon savings
Six-Point Quality Protocol
Every order passes through our six-point quality protocol before shipping: (1) Dimensional check — random sampling of 10% of pieces verified against specifications with digital calipers; (2) Moisture check — every piece scanned with a pinless meter, readings logged; (3) Grade check — visual inspection of every piece against the specified grade standard; (4) Surface check — every piece inspected for mill marks, tear-out, and surface defects; (5) Metal check — final metal detection scan on all pieces; (6) Count check — physical count verified against order quantity. If any checkpoint reveals a failure, the affected material is pulled, reworked or replaced, and re-inspected before the order proceeds.
Material Passport
Every order ships with a material passport — a document that traces the wood from its source through every step of our process to the customer's hands. The passport includes: source identification (building address, type, approximate age), salvage date, species identification (method and confidence level), structural and character grade, processing steps completed (de-nailing, kiln drying, milling specifications), moisture content readings at multiple stages, and the name of the quality control inspector who signed off. For green building projects, the passport is accompanied by a sustainability certificate documenting estimated CO₂ savings, tree equivalents preserved, and landfill diversion weight.
Equipment
- Digital calipers (0.001-inch resolution)
- Delmhorst pin moisture meters
- Wagner Orion pinless moisture meters
- Profile gauges and go/no-go fixtures
- Metal detection wands for final scan
- Digital scale for weight verification
Time Estimate
Quality control inspection: 15-45 minutes per order depending on size and complexity. Material passport preparation: 15-30 minutes.
Safety Protocol
Quality control area is climate-controlled to prevent moisture content drift during inspection. Lighting is maintained at 500 lux minimum for accurate visual inspection.
Delivery & Support
We offer full delivery service throughout the tri-state area with careful handling, proper stacking, and site-specific logistics planning. Our delivery team understands the unique challenges of delivering materials in New York City — narrow streets, walk-up buildings, tight elevator shafts, and rooftop projects. We also provide ongoing technical support for installation guidance, maintenance questions, and follow-up sourcing needs.
Quality Checkpoints
- Flatbed delivery for large orders with forklift offloading capability
- Enclosed truck delivery for weather protection on sensitive materials
- Liftgate service for ground-level unloading where dock access is unavailable
- Stair carry and hand-delivery service for walk-up buildings and interior spaces
- Crane and hoist coordination for rooftop and upper-floor deliveries
- Site-specific delivery planning including street access, parking, and building access assessment
- Delivery window scheduling to coordinate with general contractor site schedules
- Post-delivery technical support for installation, finishing, and maintenance questions
NYC Delivery Logistics
Delivering building materials in New York City requires specialized knowledge and planning. Our logistics coordinator, Maria Gonzalez, assesses every delivery site before scheduling: street width and truck access, parking and loading zone availability, building access (dock, street level, stair carry, elevator), floor destination, time-of-day restrictions (many Manhattan buildings restrict deliveries to morning hours), and any special equipment needs (liftgate, hand truck, furniture dolly, crane). For complex deliveries — upper floors of walk-up buildings, rooftop installations, or tight basement access — we provide a detailed logistics plan and quote in advance.
Technical Support & Follow-Up
Our relationship with clients does not end at delivery. We provide ongoing support including: installation guidance for flooring, paneling, siding, and structural applications; finishing recommendations specific to reclaimed wood species and conditions; maintenance advice for long-term care; and follow-up sourcing for additional material needs. Our team is available by phone and email during business hours, and we maintain detailed records of every order so that if a client needs to match material from a previous purchase, we can identify the exact species, grade, and source.
Equipment
- Ford F-450 flatbed with 5,000 lb capacity
- 16-foot enclosed delivery truck
- Liftgate (2,000 lb capacity)
- Pallet jack and hand trucks
- Furniture dollies for interior delivery
- Moving blankets and edge protectors for damage prevention
Time Estimate
Standard delivery within NYC: same-day to 3 business days. Long Island, Westchester, NJ, CT: 2-5 business days. Freight shipping beyond service area: 5-10 business days.
Safety Protocol
All delivery staff are trained in safe lifting techniques. Maximum individual lift weight: 75 lbs. Two-person carry required for all timbers and oversized pieces.
Zero-Waste Commitment
Waste Minimization at Every Step
Our zero-waste philosophy extends throughout every stage of our process. Here is where our byproducts go:
| Byproduct | Source Step | Destination |
|---|---|---|
| Nails, screws, metal fasteners | De-Nailing | Metal recycler in Long Island City |
| Sawdust and wood shavings | Milling | Animal bedding for Hudson Valley farms |
| Offcuts (usable size) | Milling | Sold as craft/project wood or donated to schools |
| Small offcuts and scraps | Milling | Kindling sold to wood-fired restaurants |
| Bark and unusable wood | Inspection | Composting facility in Queens |
| Contaminated material | Inspection | Certified hazardous waste disposal (rare — less than 2% of intake) |
Our Standards
Quality Standards & Tolerances
We hold ourselves to professional standards that match or exceed those of conventional lumber suppliers. Reclaimed wood requires additional quality considerations beyond what new lumber demands — particularly around metal detection, contamination screening, and consistent moisture content after kiln drying.
| Parameter | Standard | Method |
|---|---|---|
| Dimensional Tolerance | ± 1/32" | Digital caliper measurement, 10% random sampling |
| Moisture Content (Interior) | 6-8% | Pin and pinless meter, every piece scanned |
| Moisture Content (Exterior) | 12-15% | Pin and pinless meter, every piece scanned |
| Metal Detection | Zero metal | Double electromagnetic scan (pre and post de-nailing) |
| Heat Treatment | 160°F / 30 min | Core probe temperature logging per ISPM-15 |
| Surface Flatness | ± 1/64" per foot | Straightedge check on planed/surfaced material |
| Profile Accuracy (T&G, etc.) | ± 1/64" | Go/no-go gauge and test assembly |
Ready to Start a Project?
Whether you need 10 boards or 10,000, our process ensures consistent quality and full traceability. Every order includes a material passport and sustainability certificate at no additional cost.