This is a story of a 215 year old beam: In 2005 we at Volterra Architectural Products started looking for a huge beam (something 36" in height) that we could make a mold of and replicate for decades. After a few years we found it!!!  In northern Oregon we found a reclaimed timber that was saved from a fire in an old industrial building built in 1920. This real wood beam was 10" wide, 32" tall and 48' long and in phenomenal condition. We had it cut in half and shipped to us in two pieces. One side of the beam had been charred and the other side looked great. To build a mold of this monster beam we needed to plane it flat and smooth on one side.  We hand planed for two days to get the beam thin enough to put in our 40" planer and created 125 cubic feet of saw dust. Once this was complete we sandblasted the real wood beam in critical light which took another few days. Now that the texture was complete we took the beam into the mold department and spent another few days repairing the nail holes and cracks with molding clay. We then poured our silicone rubber over the part and immediate after that created exact duplicate parts and archived the real wood beam. This whole process took almost two months with 500 man hours - and we ended up with the largest mold in the industry 1" x 31" x 288" - wow!!! That is a 62 square foot part which no one else has even come close to accomplishing. Now the fun part - building hollow fake beams and saving tens of thousands of trees for many decades. Since our faux wood beams are built out of this giant plank at 1" in wall thickness - every beam that we build saves a tremendous amount of board feet. Our 12" x 12" by 20' long beam will weigh 60 pounds and will have 60 board feet of material and a real wood beam will have 240 board feet and will weigh over 400 pounds. A typical living area will have 8-10 of these beams which would save 8-10 large trees and over 2000 board feet of material and in the last few years we have saved a few million board feet of material.