Faux Wood Trusses

Faux wood trusses

When you walk into a space, one of the first things you notice is the ceiling. And when you see faux wood trusses overhead, the entire room instantly gains character. As experts in the production of architectural elements, when we see beams on a ceiling, we immediately look at them as engineers. We see load distribution, installation logistics, scheduling risks, budget limitations, and the responsibility the architect or designer carries in front of the client.

And precisely because we see all these nuances, we know exactly how to create faux wood trusses that meet every one of these critical requirements. That is why the beams we produce stop being just décor. They become a practical, engineering-friendly, project-saving solution.

It’s a solution that helps mask mechanical systems, wiring, and other utilities. It provides a predictable, high-quality result and eliminates the need for additional structural reinforcement. And at the same time, the visual impact decorative beams have on a space is incredibly strong — they give it character, establish rhythm, define direction, and unify the entire environment.

Over 25 years we’ve seen the same situation play out countless times: massive timber trusses look beautiful on a concept board, but once structural calculations begin, the weight starts complicating everything. During installation, issues multiply. Faux wood trusses eliminate that pain. Lightweight, strong, fully customizable and visually identical to real wood, they don’t overload structural systems, don’t require cranes, and meet architectural and building standards for decorative, non-load-bearing elements, including dimensional tolerances, fire-safety spacing and clearance around MEP systems.

With faux wood beam trusses, architects gain freedom in form, developers gain predictability in cost and schedule, and contractors get elements that are genuinely easy to install. Everything is produced in the USA at our own facility, supported with full technical documentation, 3D models and a 20-year warranty.

What faux wood trusses are from a technical perspective

These are ceiling-mounted structures. They are non-load-bearing and serve a purely decorative purpose. They are made from high-density architectural foam with a protective composite shell. This shell fully replicates the texture, depth, and natural characteristics of real wood. Each structural element is essentially a multi-layered assembly:

• foam core with a density of approx. 2.5–3.0 lb/ft³
• 3–5 mm impact-resistant coating
• multi-stage wood-grain finishing
• integrated blocking for mounting hardware

Each faux wood ceiling truss is manufactured with precise geometry — up to ±1/16", which matters in modular grids, long spans and high-end architectural builds.

Trusses are engineered as decorative elements that:

• never replace load-bearing structural systems
• are calculated for weight and mounting points so your engineer can easily incorporate them
• meet architectural and building standards for decorative components, including clearance for sprinklers, lighting, and access to utilities

Materials, technology and quality control

We use architectural foam and composite coatings specifically designed for faux wood trusses.

Performance in real conditions:

• typical 10" × 12" × 20 ft faux wood beam truss weighs 60–90 lb vs. 350–400 lb for timber
• coating impact resistance: 2.5–3.0 ft·lb without visible surface damage
• thermal expansion between −20 and +120 °F is approx. 0.04" per 10 ft
• stable geometry regardless of humidity; no warping, cracking or cupping

They undergo several stages of quality control:

• Dimensional verification: We check diagonals, angles, height and width according to all parameters provided in the production faux wood trusses.
• Coating adhesion testing: This ensures that the protective coating is durable and reliable, especially since many of our architectural elements are used outdoors.
• Texture and color matching to approved samples: Every element is compared to 3D models and client-approved samples, ensuring precision in texture, finish and color.
• Packaging vibration and impact testing: Ensures oversized or large trusses arrive in perfect condition.

Each faux wood truss is delivered fully finished and painted. No additional treatment, staining or tinting is required on site.

Variants and applications of faux wood trusses

We manufacture standard configurations, but our primary specialization is unique, fully custom solutions highlighting the project's strengths and character.

• King Post Truss: classical type, 10–26 ft spans. Applications: hotel lobbies, community entrances, restaurants with open ceilings. Example: Orlando resort lobby, 80 lb trusses installed by two workers in two days.
• Queen Post Trusses: stretched horizontal aesthetic, larger spans. Applications: luxury residences, clubhouses, waterfront restaurants.
• Scissor Trusses: dynamic intersecting diagonals. Applications: event halls, chapels, conference centers.
• Hammer Beam Trusses: historic-style with dramatic proportions. Applications: clubhouses, large residences, ceremonial halls. Example: Naples, FL, 30-ft trusses, installed onto steel with no redesign.
• Box-beam and coffered systems: modular, for coffered/grid ceilings. Applications: offices, hotel lobbies, retail interiors.

Installation, documentation and compliance

We do not perform the installation ourselves, but we design every element so that installation crews can complete the process quickly and as efficiently as possible. To achieve this, we prepare:

• shop drawings with sections, attachment points and dimensions
• complete mounting plans aligned to the architectural grid
• weight specifications for structural coordination
• 3D files on request for BIM integration

All elements comply with architectural and building norms for decorative, non-load-bearing components, including:

• clearance to sprinklers and lighting
• fire-safety spacing
• access to utilities

Thermal expansion allowances, as well as precise and accurate labeling on all faux wood trusses, are always taken into account. We also deliver our faux wood trusses and components in partially or fully assembled sections whenever their dimensions and transportation logistics allow. We do this to minimize any on-site adjustments, knowing that factory-made joints are far cleaner and virtually invisible compared to assembling them in the field.

Delivery is arranged through transportation partners we have worked with for many years—companies we trust to handle even oversized or irregularly shaped architectural products with care and consistency.

Why do architects, contractors, and developers choose us?

• Made in USA production — complete quality control, no third-party factories
• Custom design capability — from historical reproductions to modern minimalist concepts
• Precise integration into your drawings — DWG/Revit-ready, exact dimensions
• Lightweight construction — no structural reinforcement, no cranes
• Lower total cost of ownership — major savings in installation, logistics and long-term upkeep
• Budget flexibility — multiple detail levels and finishing options
• 20-year warranty
• Samples and 3D previews — simplified approvals with your clients
• Personal project manager — one person who always knows your status
• In-house foam manufacturing — possibility to fabricate matching columns, beams, façades and more
• Free storage — if your jobsite isn’t ready yet

Many clients point out that when they switch to architectural foam elements after years of working with wood or metal, the overall project savings in logistics, procurement, and labor often reach 30–50% — all without sacrificing visual aesthetics. Faux wood trusses are not just a budget-friendly alternative to real timber; they are a modern, high-quality architectural tool that can deliver results even more impressive than natural materials.

They provide economic predictability while offering complete design freedom. In fact, many of our foam elements that replicate wood or metal often look even more natural than the materials they imitate — richer in texture, more consistent in tone, and visually more refined. This is possible because we can create the ideal look of luxurious, perfectly grained wood, something that natural timber doesn’t always offer due to its imperfections.

At the same time, these products are lightweight, strong, fully customized for your project, and compliant with all architectural and building regulations, including fire-safety standards. They maintain the engineering efficiency of the project while delivering a premium, high-end aesthetic identical to — or better than — natural materials.

We manufacture everything in the USA and provide every project with a complete technical documentation package, including detailed drawings and specifications. We coordinate directly with your engineering team and deliver all elements fully finished and ready for installation.

If your project involves high ceilings, exposed beams or decorative trusses — the most effective next step is simple: send us your drawings and request a proposal. We’ll help you choose the optimal solution for your design, engineering requirements and schedule.