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Featured Design Installation: Private Residence, Rhinecliff, NY

Here's a little sneak peak at a new design installation that is currently still under construction in Rhinecliff, New York.

Located in one of the oldest hamlets along The Hudson River, this private residence, designed by local architect Warren Temple Smith, features several products from The Hudson Company's full product line, including Reclaimed Softwood Joists, Reclaimed Barn Siding [Brown Board], and Reclaimed Hemlock [Surfaced Mushroom Wood].

Above right you will see our Reclaimed Factory Maple used in an engineered chevron pattern designed to work with a set of bi-fold doors. Above left, you can see new structural beams custom-wrapped with Reclaimed Barn Siding [Brown Board] to introduce an weathered patina to the home's interior aesthetic (note the chevron bi-fold doors in the background). In the same image, below the large exposed beams, you will notice Reclaimed Softwood Joists installed above the kitchen.

Stay tuned for more photos and updates on this design installation in the weeks to come.

Click here for more examples of Residential Design Installations featuring Hudson Company wood products and design solutions.

Crafting The Whitney Floors | Part 2

Writing for The New York Times on April 19, Michael Kimmelman described the new Whitney Museum of American Art this way:

'There’s a generosity to the architecture, a sense of art connecting with the city and vice versa...
Inside, irregularly weathered pine floors recycled from old factories temper a language of concrete and steel. Those same industrial materials break up the mass of the building on the outside, by turns refracting and absorbing sunlight, nudging upward, gently, the scale of a swiftly growing neighborhood.'

The story behind these 'irregularly weathered pine floors recycled from old factories' is, in fact, a rather remarkable one - the journey of rough, antique, and landfill-bound timbers carefully re-imagined and re-engineered as the flooring for New York City's newest architectural landmark.

Custom Milling The Whitney Floors

After reclaiming the raw timber materials from inactive American factories (Phillip Morris, Maidenform, Paul G. Mehlin & Sons Piano Company), The Hudson Company embarked on the fully-integrated, custom milling process, in collaboration with Cooper Robertson and The Renzo Piano Building Workshop, the museum's lead architects. 

The final Whitney installation exceeds 65,000 square feet of Reclaimed Heart Pine [Chalk Finish] flooring throughout all of the galleries and administrative offices.  In order to deliver the final product, The Hudson Company custom milled over 270,000 board feet of reclaimed timbers. These sizeable timbers ranged in size from 4” x 17” x 22’ to 11” x 17” x 24’, some weighing in excess of 1,200 pounds.

Once the raw material arrived at our Pine Plains, NY facility, metal detectors were used to locate old fasteners (nails, bolts, screws) embedded within the timbers, and then all unwanted debris is removed by hand.

Next, utilizing our 75 HP fully hydraulic 6” double edge blade saw mill, we milled the timbers into manageable dimensions (1.75" x 10" x 8-20').  Because the Whitney floor was uniquely designed to be 1.5” x 8,” we oversized the the flooring planks to 1.75” x 10" and then kiln dried each plank to 165 degrees Fahrenheit eliminating any remaining insect life and setting the pitch for stability and proper finishing.

From here, the Whitney floors went through the remaining steps of The Hudson Company's hands-on, custom milling process: the planks were re-graded, planed, ripped, molded, and checked for defects and unwanted irregularities before delivery.

Click for more information about The Hudson Company, our team, and for galleries of our reclaimed and custom-milled flooring installation projects.

Click to watch The Hudson Company sourcing and milling video.

Inside The Hudson Company's Pine Plains, NY Mill.

Inside The Hudson Company's Pine Plains, NY Mill.

Milling reclaimed material, Pine Plains, NY.

Milling reclaimed material, Pine Plains, NY.

De-nailing the reclaimed industrial timbers at the Pine Plains, NY Mill.

De-nailing the reclaimed industrial timbers at the Pine Plains, NY Mill.

Milling reclaimed material, Pine Plains, NY.

Milling reclaimed material, Pine Plains, NY.

Reclaimed Heart Pine [Chalk Finish] planks on site at the new Whitney Museum, ready for Install.

Reclaimed Heart Pine [Chalk Finish] planks on site at the new Whitney Museum, ready for Install.

Crafting The Whitney Floors | Part 1

In last week’s New York Magazine, journalist Jerry Saltz reviewed the new Whitney Museum of American Artdesigned by Renzo Piano Building Workshop and Cooper Robertson Architects and praised The Hudson Company’s Reclaimed Heart Pine [Chalk Finish] floors as “perfect.”  

But long before the finished floors were ready for the feet of thousands of artists, art-lovers, and visitors to the new museum, they were the antique timbers of abandoned industrial buildings, destined for the landfill - until they were reclaimed by The Hudson Company.

In order to meet the design specifications of the architects, The Hudson Company custom-milled over 270,000 board feet (the equivalent of 27 tractor trailer loads) of reclaimed, antique Heart Pine sourced from the Phillip Morris factory in Louisville, KY, the Paul G. Mehlin & Sons Piano Company in New York, and the Maidenform Brands Factory in Bayonne, NJ.

In the photos below you can see the Heart Pine timbers as they pass through the steps of being demolished, reclaimed, denailed, kiln dryed, and milled at The Hudson Company mill in Pine Plains, NY. 

Click here to learn more about The Hudson Company's Reclamation Process.

Click here to see photos of the finished Reclaimed Heart Pine [Chalk Finish] floor at the new Whitney Museum of American Art.

Demolition of Phillip Morris Factory, Louisville, KY.

Demolition of Phillip Morris Factory, Louisville, KY.

Demolition of Phillip Morris Factory, Louisville, KY.

Demolition of Phillip Morris Factory, Louisville, KY.

Raw Material, at The Hudson Company Mill, Pine Plains, NY.

Raw Material, at The Hudson Company Mill, Pine Plains, NY.

De-nailed raw material, ready for milling at The Hudson Company Mill, Pine Plains, NY.

De-nailed raw material, ready for milling at The Hudson Company Mill, Pine Plains, NY.

Timbers ready for the kiln-drying process, Pine Plains, NY.

Timbers ready for the kiln-drying process, Pine Plains, NY.

Kiln-dryed timbers, ready to be custom milled for The Whitney Museum of American Art.

Kiln-dryed timbers, ready to be custom milled for The Whitney Museum of American Art.