A Chef’s Kitchen - Custom Butcher’s Block Benchtop
July 2024
In the leafy suburb of Marrickville, Sydney, Emily and Chris set out on a journey to breathe new life into a 1930s bungalow. Their vision? A home that harmonises functionality with timeless charm, centered around a bespoke kitchen benchtop crafted from end grain pieces of recycled timber.
Photographer: Rohan Venn
Photographer: Rohan Venn
Emily Sandstrom of Sandstrom Architects, and Chris, a former chef and restaurateur (now leading the culture team at Australian design tech startup, Canva) envisioned more than just a functional kitchen—they aimed for a centerpiece that would stand the test of time.
As part of the broader rejuvenation and renovation of the house, Emily and Chris approached our team of designers to assist in the design and making of a custom-designed kitchen island benchtop.
Emily and Chris wanted the central island bench made like a butcher’s block. The term ‘butcher’s block’ refers to a surface constructed of multiple hard timber blocks, arranged with end-grain facing upwards and in a checkerboard pattern to minimise warping and increase stability. They are glued together to create a solid block. Butcher’s block benchtops are substantially thicker and heavier than standard timber kitchen benchtops, and the end grain of timber is harder and more resistant to abrasion than the face of the boards.
Working within a brief provided by Emily and Chris, our in-house designer Samantha Foster was able to develop a design solution meeting both the requirements of the brief and working with the natural tendencies of recycled timber.
Working Through the Challenges with Designer Samantha Foster
The project encountered early challenges — initial plans for a thick ply base proved unfeasible due to the weight and cross-directional movement that would be expected of such a large butcher’s block benchtop. A normal timber benchtop only moves across it’s width, but an end grain bench top expands and contracts over it’s length as well, so the total natural movement of the timber is much greater.
To solve this, we designed a custom powder-coated steel subframe hidden by a 105mm thick edge. The frame spans between two recycled brick underbench walls that enclose the lower cabinetry of the island bench, providing structural stability and allowing natural airflow to the underside of the timber.
We also calculated the likely movement of the end grain benchtop, and then incorporated perimeter offsets and slotted holes in steel frame to accommodate the timber's seasonal expansion and contraction.
Timber can fluctuate in size with changing humidity and weather conditions, so it’s really important to design with this in mind. This is why architects and builders love working with our team of designers here at Thor’s Hammer—between us we have decades of experience designing and building with recycled hardwood timber. We know how the timber will behave in different designs, climates and applications, and we always try and bring that understanding to every project.
Photographer: Ellie Keft
Custom Butcher’s Block Benchtop Design Features
In our workshop, our joinery team made the kitchen benchtop by making a much longer benctop, and then cutting into short lengths and then re-gluing it together again with the end grain facing upwards—the end result showcasing more than 450 individual blocks!
Building a benchtop with the end grain facing up makes it stronger and more durable—ideal as a butcher’s block where very sharp knives will be used on it daily!
The vertical wood fibres handle cuts and impacts better, absorbing pressure and resisting dents. It also helps prevent warping and splitting since it deals with moisture more evenly. Plus, the end grain's unique pattern looks great and holds up well over time, making it perfect for surfaces that see a lot of use.
Emily, Chris and Samantha landed on our dense browns mix as the timber species choice for this project. A mix of blackbutt and other dense brown recycled hardwoods, they chose this species mix for its minimal gum vein and resin content, which would be ideal for showcasing the intricate patterning of the end grain.
PRODUCT End-Grain (Butcher’s Block) benchtop
TIMBER SPECIES Dense browns
PROCESSING & FINISH Polyurethane finish
LEARN MORE: CUSTOM BENCHTOPS
Being a small part of Emily and Chris' 1930s bungalow revitalisation was a rewarding project for us here at Thor’s Hammer, and we were really happy with how it turned out.
We relish the opportunity to work with architects and builders who have a strong commitment to sustainability, and we love going the extra mile to puzzle out some of these trickier design jobs. It keeps us on our toes!
If you're working on a furniture or joinery project where you need expert advice on designing and building with hardwood timber, get in touch with us today.
Photography Rohan Venn & Ellie Keft