Core Services
Processing Capabilities
We offer a complete suite of wood processing services designed specifically for reclaimed lumber. Each service can be ordered individually or combined into a full processing package tailored to your project requirements.
De-Nailing
Every piece of reclaimed wood enters our facility riddled with nails, screws, staples, and other embedded metal. Our process starts with electromagnetic detection that scans each board for ferrous and non-ferrous metals down to 1/16 inch in diameter. Flagged fasteners are extracted by hand using specialized tools that minimize wood damage. We guarantee 99.9% metal-free stock — critical for safe milling and to protect downstream equipment.
Planing & Surfacing
Our spiral-cutterhead planer and 52-inch wide-belt sander work together to produce smooth, dimensionally consistent surfaces while preserving the character that makes reclaimed wood unique. We offer multiple finish levels: skip-planed (light pass, retains most character), S2S (two smooth faces), and S4S (four smooth faces). Our spiral cutterhead is specifically chosen for reclaimed work because it significantly reduces tear-out on the irregular grain patterns common in old-growth and salvaged timber.
Re-Sawing
Re-sawing transforms thick timbers into thinner boards, dramatically increasing the yield from heavy salvaged stock. Our 36-inch horizontal band saw can slice beams up to 36 inches in diameter into boards as thin as 1/4 inch. This is how we produce paneling, thin cladding, and veneers from material that would otherwise only be usable as structural beams. We use thin-kerf blades to minimize waste — every fraction of an inch matters when working with irreplaceable old-growth timber.
Kiln Drying
All reclaimed lumber intended for interior use must be dried to an appropriate moisture content — typically 6-12% depending on the application and local climate conditions. Our dehumidification kiln handles up to 5,000 board feet per charge and uses programmable schedules that balance speed with wood quality. For thick stock (3 inches and above) that would require weeks in a conventional kiln, our radio frequency kiln completes the process in 1-3 days by heating the wood from the inside out.
Custom Profiling
Our four-head molder produces any profile you need from reclaimed stock: tongue-and-groove (standard and end-matched), shiplap, nickel-gap shiplap, bead board, crown molding, baseboard, casing, chair rail, and fully custom profiles. We stock over 100 standard profile knives and can grind custom knives to match existing millwork or realize new designs. Minimum run for standard profiles is 100 lineal feet; custom knife grinding requires 200 lineal feet minimum.
Grading & Sorting
Proper grading is what separates professional reclaimed lumber from random salvage. Every piece we process is graded for structural integrity, species-identified using visual and microscopic analysis, and categorized by dimension and quality. We use a grading system aligned with NHLA standards but adapted for the unique characteristics of reclaimed wood. Grades include Select, #1 Common, #2 Common, and Character/Rustic. Each piece or bundle is labeled with species, grade, dimensions, and moisture content.
Our Facility
Equipment List
Our Long Island City mill is equipped with industrial-grade machinery selected specifically for reclaimed wood processing. The challenges of salvaged lumber — embedded metal, irregular dimensions, variable moisture, and mixed species — require robust equipment and experienced operators.
Electromagnetic De-Nailer
60" capacity, detects ferrous and non-ferrous metals to 1/16" diameter
Locates and flags embedded nails, screws, staples, and metal fragments before any cutting operation.
Wide-Belt Sander
52" wide, dual-head, 60–220 grit range
Smooths surfaces while preserving wood character. Adjustable pressure and grit for skip-planed to fully surfaced finishes.
Thickness Planer
24" wide, spiral cutterhead, 1/64" depth adjustment
Planes boards to precise, consistent thickness. Spiral head reduces tear-out on difficult grain patterns common in reclaimed wood.
Horizontal Band Saw (Re-Saw)
36" log capacity, 2" to 1/4" kerf blade options
Re-saws thick timbers into thinner boards for paneling, veneers, and cladding. Maximizes usable material from heavy stock.
Vertical Band Saw
24" throat, variable speed, contour cutting capability
Cuts curves, irregular shapes, and live-edge profiles. Used for custom architectural elements and furniture components.
Straight-Line Rip Saw
Laser-guided, 16" cutting height
Establishes straight, parallel edges on rough boards for consistent widths and clean joint faces.
Molder / Profiler
4-head, 8" × 6" capacity, 100+ profile knives
Produces tongue-and-groove, shiplap, bead board, crown molding, baseboard, and custom profiles.
Dehumidification Kiln
5,000 BF capacity per charge, programmable PLC controller
Dries reclaimed lumber to 6-12% moisture content while heat-treating to eliminate insects and pathogens.
Radio Frequency Kiln
1,000 BF capacity, rapid cycle for thick stock
Accelerated drying for heavy timbers and thick slabs that would require weeks in a conventional kiln.
CNC Router
4' × 8' table, 3-axis, vacuum hold-down
Precision cutting for custom inlays, sign work, decorative panels, and prototype components.
Radial Arm Saw
16" blade, 24" crosscut capacity
Crosscutting boards to length, trimming damaged ends, and preparing material for further processing.
Dust Collection System
15,000 CFM cyclone separator, HEPA filtration
Captures dust and debris from all processing stations to maintain air quality and meet OSHA exposure limits.
Specifications
Processing Capabilities Matrix
The table below details the dimensional limits and tolerances for each processing service. Material outside these ranges may be processable with special handling — contact us to discuss.
| Capability | Min Thickness | Max Width | Max Length | Tolerance | Notes |
|---|---|---|---|---|---|
| De-Nailing | Any | Any | 40' | 99.9% metal-free | Electromagnetic detection + hand extraction |
| Planing (thickness) | 3/8" | 24" | 20' | +/- 1/64" | Spiral cutterhead, minimal tear-out |
| Wide-Belt Sanding | 1/4" | 52" | Continuous | +/- 1/32" | 60-220 grit, adjustable pressure |
| Re-Sawing | 1/4" output | 36" round | 24' | +/- 1/16" | Thin kerf blade minimizes waste |
| Straight-Line Rip | 1/2" | No limit | 20' | +/- 1/32" | Laser-guided for precision |
| Profiling (T&G, shiplap) | 1/2" | 8" | 20' | +/- 1/64" | 100+ standard and custom profiles |
| Kiln Drying (standard) | Any | Any | 16' | 6-12% MC | 7-14 day cycle, 5,000 BF capacity |
| Kiln Drying (RF rapid) | 2" | 24" | 12' | 6-12% MC | 24-72 hour cycle for thick stock |
| CNC Routing | 1/4" | 48" | 96" | +/- 0.005" | 3-axis, complex shapes and inlays |
Kiln Drying
Kiln Drying Schedule Details
Kiln drying is one of the most critical steps in preparing reclaimed lumber for interior use. Improperly dried wood will warp, cup, crack, and gap after installation. Our programmable dehumidification kiln follows species-specific schedules that balance drying speed with wood quality.
The schedules below are typical for reclaimed hardwoods starting at 15-25% moisture content (air-dried or partially dried). Green stock (above 25% MC) requires an extended pre-drying phase. All kiln charges include heat treatment to 133°F core temperature for a minimum of 30 minutes to meet ISPM 15 phytosanitary requirements.
| Thickness | Pre-Dry Phase | Final Dry Phase | Total Cycle | Target MC |
|---|---|---|---|---|
| 4/4 (1") | 2-3 days | 4-5 days | 7-8 days | 6-8% |
| 5/4 (1-1/4") | 3-4 days | 5-6 days | 8-10 days | 6-8% |
| 6/4 (1-1/2") | 4-5 days | 5-7 days | 9-12 days | 6-8% |
| 8/4 (2") | 5-7 days | 7-10 days | 12-17 days | 6-10% |
| 12/4 (3") | 7-10 days | 10-14 days | 17-24 days | 8-12% |
| 16/4 (4") and above | RF kiln recommended | RF kiln recommended | 3-7 days (RF) | 8-12% |
Schedules are approximate and vary by species, initial moisture content, and ambient conditions. We monitor moisture content continuously during drying and adjust schedules as needed.
De-Nailing
De-Nailing Process in Detail
De-nailing is the first and arguably most important processing step. Reclaimed lumber from demolition and deconstruction sites is typically loaded with cut nails, wire nails, screws, staples, lag bolts, and miscellaneous metal — sometimes dozens of fasteners per board. This metal must be removed before any cutting or planing can occur safely.
Our process uses a two-stage approach. First, each board passes through our electromagnetic metal detector, which flags the location of every metal object to a resolution of 1/16 inch. The detection system identifies both ferrous (iron-based) and non-ferrous (copper, aluminum, brass) metals, catching fasteners that visual inspection would miss.
Second, our trained technicians extract each flagged fastener by hand using specialty de-nailing tools designed to minimize wood damage. Cut nails (the square, hand-forged type common in pre-1900 construction) require particular skill to remove without splitting the surrounding wood. After extraction, boards pass through the detector again to confirm they are clean. We guarantee 99.9% metal-free stock.
Before De-Nailing
- Boards contain embedded nails, screws, staples, bolts
- Metal is often hidden below the surface (broken off, painted over)
- Cannot be safely milled — metal destroys saw blades and planer knives
- Surfaces are rough, dirty, and covered in paint or finish
- Handling hazard from protruding fasteners
After De-Nailing
- 99.9% metal-free — safe for all milling operations
- Small nail holes remain (add character, can be filled if desired)
- Each board has been individually handled and visually inspected
- Defective sections identified and marked for trimming
- Ready for kiln drying, planing, or any downstream processing
Profiling
Custom Profiling Options
Our four-head molder transforms surfaced reclaimed boards into finished, profile-milled products ready for installation. We maintain an extensive library of standard profiles and can create custom profiles to match existing millwork or realize new designs.
Tongue & Groove (standard)
Classic interlocking joint for flooring and paneling. Standard offset tongue centered on board thickness.
Tongue & Groove (end-matched)
T&G on all four sides including ends for seamless installation without staggered joints.
Shiplap
Overlapping rabbet joint for wall cladding and siding. Clean-line contemporary look with shadow lines.
Nickel-Gap Shiplap
Shiplap with a consistent reveal gap between boards. Popular for modern farmhouse and coastal aesthetics.
Bead Board
V-groove or bead detail on one face. Traditional wainscoting and ceiling treatment profile.
Board & Batten
Wide boards with narrow battens covering joints. Vertical installation for walls and siding.
Crown Molding
Custom crown profiles from reclaimed stock. Multiple standard profiles available, or supply your own template.
Baseboard & Casing
Millwork profiles for baseboards, door and window casings, chair rails, and picture rails.
Custom Templates
Supply a sample or drawing and we replicate the profile. Minimum 200 lineal feet for custom knife grinding.
Quality
Quality Assurance Steps
Quality control is built into every stage of our processing workflow, not applied as a final check. Here is what happens at each stage to ensure the material we deliver meets your expectations.
Intake Quality Checks
- Visual inspection for rot, insect damage, structural failure
- Species identification (visual and microscopic)
- Moisture content measurement (pin and pinless meters)
- Dimensional measurement and cataloging
- Photo documentation for provenance records
De-Nailing Quality Checks
- Full electromagnetic scan (ferrous and non-ferrous detection)
- Hand extraction of all flagged fasteners
- Second-pass detector scan to confirm 99.9% metal-free
- Visual inspection for damage caused during extraction
- Defect marking for downstream trimming
Kiln Drying Quality Checks
- Continuous moisture monitoring via kiln probes
- Core temperature verification (133°F minimum for heat treatment)
- Post-kiln moisture spot-checks with pin meter
- Inspection for drying defects (checking, warping, case hardening)
- Equalization and conditioning phase to relieve drying stress
Planing & Milling Quality Checks
- Dimensional verification with calipers after every setup change
- Surface quality check for tear-out, snipe, and machine marks
- Profile verification against spec drawings for custom profiles
- Final metal detector pass on all milled material
- Random sampling: 1 in 20 boards measured for dimensional consistency
Scheduling
Lead Times by Service Type
Lead times depend on the service, volume, and current production load. The estimates below reflect typical turnaround under normal conditions. Rush processing is available for most services at a 25-50% surcharge.
| Service | Volume | Estimated Lead Time |
|---|---|---|
| De-Nailing Only | Under 500 BF | 2-3 business days |
| De-Nailing Only | 500-2,000 BF | 3-5 business days |
| De-Nailing Only | Over 2,000 BF | 5-10 business days |
| Kiln Drying (standard) | Any (up to 5,000 BF/charge) | 7-14 days |
| Kiln Drying (RF rapid) | Up to 1,000 BF | 1-3 days |
| Planing / Surfacing | Under 500 BF | 2-3 business days |
| Planing / Surfacing | 500-2,000 BF | 3-7 business days |
| Re-Sawing | Under 500 BF | 3-5 business days |
| Re-Sawing | 500-2,000 BF | 5-10 business days |
| Custom Profiling (standard) | Under 500 LF | 5-7 business days |
| Custom Profiling (standard) | 500-2,000 LF | 7-14 business days |
| Custom Profiling (custom knife) | Any | 14-21 business days |
| Full Processing Package | Under 1,000 BF | 10-14 business days |
| Full Processing Package | 1,000-5,000 BF | 14-21 business days |
| Full Processing Package | Over 5,000 BF | 21-30 business days |
Minimums
Minimum Lot Sizes
We keep our minimums low to accommodate projects of all sizes — from a single tabletop to a full commercial fit-out. Some services have practical minimums driven by equipment setup time, and custom work has minimums that reflect the investment in tooling.
De-Nailing
No minimumWe will de-nail even a single board
Kiln Drying
No minimum (batched with other orders)Dedicated kiln charges: 1,000 BF minimum
Planing / Surfacing
No minimumSmall lots (under 50 BF) subject to setup fee
Re-Sawing
50 board feetBelow 50 BF, per-piece pricing applies
Standard Profiling (T&G, shiplap)
100 lineal feetStandard knife, no setup charge
Custom Profiling (new knife)
200 lineal feetKnife grinding charge applies (typically $150-$300)
Full Processing Package
No minimumUnder 100 BF subject to setup fee
Before & After: Full Processing
Before Processing
A typical lot arrives as rough, dirty timbers and boards pulled from a demolition or deconstruction site. The wood is loaded with nails — often 20-50 per board — and covered in layers of paint, plaster dust, and grime. Moisture content is variable (15-30%+). Dimensions are nominal and inconsistent. The wood smells of age and old buildings.
- Moisture content: 15-30%+ (variable)
- Surface: rough, dirty, painted, nail-laden
- Dimensions: nominal, inconsistent
- Metal: dozens of fasteners per board
- Status: cannot be safely milled or installed
After Processing
The same lot emerges as clean, surfaced lumber with consistent dimensions, verified species labeling, and documented moisture content. The grain patterns, color variations, and subtle character marks (nail holes, saw marks, patina traces) that give reclaimed wood its unique appeal are preserved while the surface is smooth and ready for finishing.
- Moisture content: 6-12% (verified, consistent)
- Surface: smooth, clean, character preserved
- Dimensions: precise to +/- 1/64 inch
- Metal: 99.9% removed, detector-verified
- Status: ready for finishing and installation
Toll Processing
Bring Your Own Wood
Have reclaimed wood that needs processing? We offer toll processing — bring your material to our facility and we will de-nail, dry, plane, and mill it to your specifications. You keep the wood; you just pay for the processing services.
Toll processing is popular with contractors who salvage material from their own renovation projects, woodworkers who find reclaimed stock from private sources, and property owners who want to repurpose lumber from structures on their land. We process your material with the same care and precision we apply to our own inventory.
Request Processing QuoteFAQ
Frequently Asked Questions
What metal detection and de-nailing capabilities do you use?
We run electromagnetic scanners and hand de-nailing, targeting 99.9% metal-free lumber before milling or drying.
Can you kiln-dry reclaimed beams safely?
Yes. We kiln-dry beams and boards with monitored moisture targets between 6–12% depending on the application.
Do you offer custom profiles and knife grinding?
We cut T&G, shiplap, flooring, siding, and can grind custom knives to match historic or architect-specified profiles.
How do you handle lumber with embedded paint or residue?
We inspect for lead, remove contaminants where possible, and can surface-plane or re-saw to expose clean material.
What’s the typical processing timeline?
Most milling jobs take 10–15 business days; rush lanes are available based on capacity and order size.