Why We Manufacture

 
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When the COVID-19 pandemic hit the United States in March, a shift from in-person to remote work swept every “non-essential” workplace practically overnight. Suddenly television news anchors were broadcasting from their homes against subdued digital backdrops. Classrooms went virtual, and students became expert “zoomers.” Museums shifted their operations to the web, and began sharing ever more content via Instagram and virtual events and tours. Novice sourdough bread enthusiasts shared their exploits on social media, while others sang the praises of a popular YouTube-based yoga teacher. Writing in the New York Times, reporter Dana Rubenstein noted that many politicians and journalists doing interviews from home were conspicuously displaying The Power Broker, Robert Caro’s massive 1974 biography of Robert Moses on their shelves, along with elegant ceramics and framed photos within view of the camera lens. (There’s even a Twitter feed that documents Power Broker sightings on TV.) It almost started to feel normal.

Of course, digital and virtual economies were vital before the pandemic, too. High school TikTok stars and Instagram influencers have real power (and make real money) these days, not as hobbyists, but as stand-up comics, singer-songwriters, and as arbiters of fashion and style. But as the experiences of brave essential workers demonstrated starkly at the pandemic’s height, digital work is limited to certain fields and certain kinds of jobs. There is no such thing as a digital emergency room doctor or EMT, or a virtual bus driver, or an online-only grocery store stocker. We live in the flesh and blood world, and we can only conduct certain aspects of our daily lives from behind a glowing screen.

 
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Like every other business, when the pandemic began, The Hudson Company had to quickly find workarounds in order to keep functioning safely. We were already doing certain things that made this transition possible: we have a website, social media feeds, we can share digital documents and images instantly, and we can communicate with clients and colleagues using video chat. But when New York State mandated that non-essential businesses close down in March, we had to close our showrooms and our Pine Plains mill. Just like companies that make fabric, tiles or lighting fixtures, there are things that simply cannot be accomplished virtually.

Take reclamation, for example: the expertise and hand skills necessary to deconstruct a barn or farmhouse are years in the making. Each old barn is unique, and our experts need to know what they’re looking at and how to deconstruct it, which is a different task every time. What kind of wood is it? How old is it? What kind of shape is it in? Then the wood comes to our mill. How should it be treated and processed? What features does our client need for a particular project? The tools and techniques required to mill and finish wood, especially to the high standards we’re known for, are not something that can be mastered overnight, nor can they be accomplished alone. Our team has years of expertise, and they work together in real time to produce the flooring and paneling we offer.

 
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New York State has started lifting some of the restrictions for non-essential businesses, but we’re still practicing social distancing, frequent handwashing and mask-wearing, and probably will continue to do so for some time. This may be our new normal. We usually hear the word “manufacture” in the context of industry, and we picture assembly lines, huge factories, and smart machines making things at high speed. But the word “manufacture” itself predates industry, and its Latin root words mean “to make” (facere) “by hand” (manus). Our digital tools, from Instagram to Zoom, have kept us connected these past few months, and we’re grateful for them. Indeed, we probably couldn’t survive without them. But if this experience has taught us anything, it’s that nothing can replace the know-how, creativity, or trained eye of a human being.

 
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Carved by Nature: the Sculptural Appeal and Origins of Mushroom Wood

 
Reclaimed, Char Dyed, Mushroom Wood paneling at McCann Erickson offices in New York City.

Reclaimed, Char Dyed, Mushroom Wood paneling at McCann Erickson offices in New York City.

The paneling that clads the elevator bank walls in McCann Erickson’s New York offices is silky black and heavily grooved, and it looks as though a sculptor has drawn a gouging tool across its shiny surface to make a pattern. But no tools were needed to craft these grooves; in fact, the wood developed these traits after years of service in the cultivation of mushrooms. Though it’s technically a mix of hemlock and cypress, we call it mushroom wood. 

Mushrooms grow wild in the woods, and thrive in dark, damp conditions where there’s plenty of decaying plant matter to provide the organism with energy—no sunlight required. To recreate these conditions, mushroom farmers set up growing beds indoors, often building structures that look a bit like the shelves inside a cheese cave, only they’re prepared with trays of manure and substrate. The beds are built from hemlock or cypress, and the substrate is typically derived from a grain like millet or rye on which the spores can grow. The manure contains enzymes which erode the growing boards over time, and after about fifteen years, they’re no longer suitable for use on the farm.

Mushrooms growing.

Mushrooms growing.

The dark and damp beds of a mushroom farm.

The dark and damp beds of a mushroom farm.

This is the moment when we harvest them: we have a relationship with mushroom growers in the mid-Atlantic region, and we regularly trade old boards for new ones. By the time we get them, the old boards have developed a rich color and texture that makes them ideal for interiors that call for rustic or boldly textured paneling. The design advantage of mushroom wood is, paradoxically, the uniformity of its quirks. The enzymatic erosion weather the wood’s surface substantially, but does so very evenly on boards as long as sixteen feet.

Harvested Mushroom Wood.

Harvested Mushroom Wood.

When the wood arrives at our mill in Pine Plains, we remove the nails, power wash it, dry it in a kiln, then mill it, and it’s ready for use. We offer mushroom wood in four ways. There are two types of mushroom wood that can be used for flooring: Backside with original saw kerf, and New Face. Backside has a rich caramel patina, while New Face is lighter, and more uniform in color throughout. The two Sculpted forms of mushroom wood are suitable for paneling or ceilings, as in this dramatic installation at the Gramercy Park Hotel. Our Sculpted Face, which can be found on the walls of Donostia Restaurant in London, is caramel-colored and has naturally sculpted and radial kerfed faces giving it a complex surface design. Our Sculpted Face can be Char Dyed, as seen in the McCann Erickson offices where it offers a dramatic, sophisticated design element that isn’t fussy.

Reclaimed Mushroom Wood adorns the ceiling of the Gramercy Park Hotel in New York City.

Reclaimed Mushroom Wood adorns the ceiling of the Gramercy Park Hotel in New York City.

Reclaimed, Sculpted, Mushroom Wood Paneling at Donastia Restaurant.

Reclaimed, Sculpted, Mushroom Wood Paneling at Donastia Restaurant.

Reclaimed, Mushroom Wood Paneling at a private residence in the desert.

Reclaimed, Mushroom Wood Paneling at a private residence in the desert.

Reclaimed Mushroom Wood, Sculpted, paneling.

Reclaimed Mushroom Wood, Sculpted, paneling.

Reclaimed Mushroom Wood, New Face, flooring.

Reclaimed Mushroom Wood, New Face, flooring.

Reclaimed Mushroom Wood, Char Dyed, paneling.

Reclaimed Mushroom Wood, Char Dyed, paneling.

Reclaimed Mushroom Wood, Backside, flooring.

Reclaimed Mushroom Wood, Backside, flooring.

 

The Hudson Company featured in the nyt

 
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Elizabeth Roberts, and architect based in Brooklyn, NY., installed natural-looking white-oak flooring from The Hudson Company in the kitchen of a TriBeCa home.  Photo by Kyle Knodell

Elizabeth Roberts, and architect based in Brooklyn, NY., installed natural-looking white-oak flooring from The Hudson Company in the kitchen of a TriBeCa home.
Photo by Kyle Knodell

A house by Di Biase Filkoff Architects in Millbrook, NY., live-sawn white oak floors with plenty of character, from The Hudson Company. Photo by Gentl and Hyers.

A house by Di Biase Filkoff Architects in Millbrook, NY., live-sawn white oak floors with plenty of character, from The Hudson Company. Photo by Gentl and Hyers.

In a farmhouse in Dutchess County, NY., Larson Architecture Works installed reclaimed heart-pine flooring from The Hudson Company. Photo by William Cole.

In a farmhouse in Dutchess County, NY., Larson Architecture Works installed reclaimed heart-pine flooring from The Hudson Company. Photo by William Cole.

 

“The floor is the base upon which all other decisions are built.”

- Tim McKeough, NYT

 
A house by Roger Ferris and Partners in Bridgehampton, NY., has flat-sawn white oak floors by The Hudson Company. Photo by Gentl and Hyers.

A house by Roger Ferris and Partners in Bridgehampton, NY., has flat-sawn white oak floors by The Hudson Company. Photo by Gentl and Hyers.


Design writer and New York Times contributor, Tim McKeough, writes about the complex decisions that face renovators when it comes to choosing the right kind of hardwood flooring. The Hudson Company founder Jamie Hammel is quoted extensively in the piece, on the topics of grain appearance (“tiger stripes” and “cathedral pattern”), lumber grading, which classifies pieces of wood according to how many or few knots they have, the difference between solid and engineered wood, and the pros and cons of various finishes. 

The article will appear in the print edition of the New York Times on January 12th.

Read the full article here

Protecting Your Floors This Winter

 
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Protecting Your Wood Floors

As the dry winter months approach, we’d like to remind all our friends, clients, and partners of the importance of monitoring the environmental conditions in your home, office, and retail spaces.

The natural expansion and contraction of wood caused by insufficient or excessive relative humidity levels can affect your wood floors.  This winter, we encourage you to monitor the conditions of your space to maintain a comfortable environment. 

Here are a few easy ways to protect and maintain your floors:

  1. Purchase a digital hygrometer.

  2. Maintain an interior temperature between 60 - 75 degrees Fahrenheit.

  3. Maintain an interior relative humidity of 35 - 55%,

For more information, please visit www.nwfa.org or contact The Hudson Company directly. 

 

INSTALLATION IN FOCUS: DOWNTOWN IN COLOR BY HALLIDAY GREER, 8th STREET, MANHATTAN

Interior design by Halliday Greer, Capella, Flat Sawn flooring by The Hudson Company, Photo by Annie Schlechter

Interior design by Halliday Greer, Capella, Flat Sawn flooring by The Hudson Company, Photo by Annie Schlechter

Interior and architectural designers Andrew Halliday and David Greer focused on chroma and pattern while thinking about their design for this bright and color bathed residential renovation in lower Manhattan.

Early in the process, the designers and owners were aligned in wanting to use a light colored floor to amplify the brightness of the space without competing with the rest of the colorful elements of the interior. They selected Capella, Flat Sawn White Oak Select Grade flooring for the project. “We wanted something light, neutral and airy so that it didn’t ever feel dark or too heavy…a clean and contemporary envelope that didn’t compete with the deep colors and patterns on the walls,” said Halliday.  “We think it looks terrific.”

Photo by Annie Schlechter, Typographic art by Russell Maret

Photo by Annie Schlechter, Typographic art by Russell Maret

Photo by Annie Schlechter

Photo by Annie Schlechter

The entryway paneling is painted a deep teal blue and creates a wonderful arrival that opens up into the rest of the bright apartment.  Bold patterned wallpapers were integrated with other graphic elements to create an environment that truly represented the owners themselves.  Russell Maret, a type designer and family member, provided some of his typographic artwork, which adorn the walls with color and symmetry. 

“Working with The Hudson Company was a terrific and seamless process,” commented Halliday, “we will use their floors many many times in the future.”

Photo by Annie Schlechter

Photo by Annie Schlechter

5 Questions With Architect Sarah Zames of General Assembly

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The Hamptons is an interesting place because it has both a very formal and a more relaxed artistic history. This project was a balance of those two ideas.
— Architect Sarah Zames
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Flooring is one of the biggest decisions you make on a project and locking that decision in in the beginning is important in order to keep the other decisions on finishes in line. What I enjoyed about The Hudson Company was the education they brought to the clients.
— Sarah Zames

Meet Sarah Zames of General Assembly

Brooklyn-based architect Sarah Zames grew up in Northwest Connecticut and has been living and designing in New York City and Los Angeles for the past two decades. After working at several international firms, including Skidmore Owings and Merrill, Tod Williams and Billie Tsien Architects, and Rafael Viñoly Architects, her attraction to the intimacy and scale of residential design led her, in 2010, to start General Assembly - a team of designers and project managers who believe that the details of a home should come from the unique, personal details of the people who live there. In addition to ground up and full renovation projects, GA designs custom lighting and furniture.

Creating A Family Refuge In The Hamptons

In 2018, The Hudson Company worked together with Sarah and GA to provide the custom milled flooring for the ‘Watermill’ project - a complete residential renovation in The Hamptons. Describing the project in their own words, GA says:

“This 3400 square foot home in the Hamptons was gutted down to the studs and rebuilt to create a family refuge from the busy city. We were inspired by the idea of juxtuposing the informality of a traditional country house with the formality that such a grand space required, in order to create something entirely unique, filling the house with our modern interpretation of some very classic details. GA handled all aspects of the process from architectural design to interior design, including all lighting, finishes and several custom designed furniture pieces.”

5 Questions with Architect Sarah Zames

After the successful completion of the Watermill project, which features Hudson Company Bare, White Oak, Flat Sawn floors, we wanted to sit down with Sarah to discuss a bit about her team’s creative process and how they brought the Watermill project to life.

First off, how did you distill the clients' needs / ideas into a clear vision for the design of this project?

The house was designed for four different people (from two different generations) to enjoy. So, we naturally had some differing opinions on style.  We wanted to make sure we were able to work the personality of everyone into the design, and took input from everyone involved. One unifying factor between everyone was their love of travel. They often traveled as a family together, and brought back some great art pieces. We made sure to find places to include those in the space. 

Clearly there is a focus on natural materials in this project—woods, marble, stone, and plants—can you talk a bit about these choices of materials and why they are a good fit for a, 'family refuge from the city?'

We tend to use natural materials in all of our projects because they are ageless and will not go out of style. For this project, using natural materials was a big part of bringing balance to the design. We combined natural materials with more modern details and, in doing so, we were able to achieve a comfortable elegance.

How did the design of this home fit into or contrast the historic design vernacular of the Hamptons?

The Hamptons is an interesting place because it has both a very formal and a more relaxed artistic history. This project was a balance of those two contrasting ideas. We wanted to maintain some of the formality, but also create a comfortable place to enjoy the weekend. We achieved this balance by creating more modern versions of some traditional details (for example, the paneling on the stairs and family room ceiling), and by bringing in natural materials that would age over time.  

It's clear that your team loves the custom details of design (from finishes, lighting, furniture, etc.). Can you talk about this high-level of creative detailing and how this style of work allows you to serve your clients and create unique design?

We feel that the best part of doing a full renovation is being able to have everything designed exactly to your taste. Designing custom details, like the brass tops to the railing balustrade, is one of the best parts of what we do. It means that the homeowners get to enjoy something that is unique to them, and we get to experiment with design and work with really great craftspeople.

Lastly, can you talk about your experience collaborating with The Hudson Company during the Watermill project?

We started working with The Hudson Company very early on in the project. Flooring is one of the biggest decisions you make on a project and locking that decision in in the beginning is important in order to keep the other decisions on finishes in line. What I enjoyed about Hudson was the education they brought to the clients. They respect the fact that [wood flooring] is a big investment and they took the time to educate the clients on the importance of quality flooring. 

Learn more about Bare, White Oak, Flat Sawn

Go inside the Watermill residential project here and here.

Project Credits:

Inside Our New Ridgefield, CT Showroom

***THIS LOCATION HAS BEEN CLOSED***

Come Visit Us In Ridgefield, CT

Opened on November 14, 2018, our Ridgefield, CT showroom was established to serve our Westchester, Connecticut, and New England clients. Designed by Brad Ford and furnished by FAIR, our newest and largest showroom will showcase over 100 flooring, paneling, and beam products.

Located on Ethan Allen Highway (Route 7), our Ridgefield Showroom is conveniently located for product viewings, consultations, and client meetings and is open by appointment Monday to Friday.

Book An Appointment or Learn More About Our Ridgefield Showroom

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Protecting Your Floors This Winter

 
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Protecting Your Wood Floors

As we approach the dry winter months, we’d like to remind all our friends, clients, and partners of the importance of monitoring the interior environmental conditions in your home, office, and retail spaces—specifically the temperature and relative humidity levels.

Natural expansion and contraction of wood can be caused by insufficient or excessive relative humidity.  So, to reduce the chance of damage to your wood floors, the National Wood Flooring Association recommends a climatic temperature of 60 - 75 degrees Fahrenheit and 35 - 50% relative humidity. 

Easy Tip For Protecting Your Wood Floors This Winter

This winter, we encourage you to closely monitor the conditions of your space and strive to create a comfortable environment for both you and your wood floor. So, here are four easy ways to protect and maintain your floors…

  1. Purchase an indoor thermometer / humidity monitor (online or from a local hardware store),

  2.  Install monitor and keep an eye on the indoor conditions during winter months,

  3. Maintain an interior temperature of between 60 - 75 degrees Fahrenheit,

  4. Maintain an interior humidity of 35 - 50%,

  5. Enjoy your wood floors for decades to come!

Questions? Learn More

*For more information, please visit www.nwfa.org or contact The Hudson Company directly.

*For more tips on maintaining and protecting your wood floors, stay tuned to this blog and follow The Hudson Company on Instagram at @thehudsoncompany.

*Plan on scheduling a visit to our NEW SHOWROOM in Ridgefield, CT, opening on 11/14/2018. More info on that to come!

 

Before And After: Reclaimed White Pine From A Finger Lakes Farmhouse

‘Rippings,’ scraps created during the process of milling Reclaimed White Pine planks at The Hudson Company Mill in Pine Plains, NY.

‘Rippings,’ scraps created during the process of milling Reclaimed White Pine planks at The Hudson Company Mill in Pine Plains, NY.

‘Before’ detail of raw material.

‘Before’ detail of raw material.

After being milled by The Hudson Co.

After being milled by The Hudson Co.

Reclaimed & Re-Milled For A Second Life

The photos above and below illustrate just one example of how The Hudson Company works to redirect historic building materials away from the waste stream and then uses our team of skilled craftspeople to re-mill this valuable material so that it can be put to new uses in a wide variety of applications.

White Pine From NY’s Finger Lakes

The planks shown here are antique pine boards salvaged from a historic farmhouse in the Finger Lakes district of NY in 2018. After being transported to The Hudson Company Mill in Pine Plains, NY, the planks were then sorted, graded, and de-nailed by hand before being re-milled.

And while it may have been hard to see the beauty in these old pine planks when they first arrived in Pine Plains, our team of pros has decades of experience in transforming gray, weather-beaten, and antique planks into stunning new floors.

See for yourself in the photos above and below.

Learn More

Explore our full range of quality flooring products.

Learn more about The Hudson Company’s FSC-certified Mill in Pine Plains, NY.

Learn more about our sustainable wood reclamation process.

The Hudson Company team hard at work de-nailing planks by hand.

The Hudson Company team hard at work de-nailing planks by hand.

The tools of the trade.

The tools of the trade.

The end result.

The end result.

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Go Behind The Scenes And Watch The Full Reclamation Process In Action