The surface and texture, the shape and form, colouring, knots, cracks and rustic character of reclaimed timber can be the essential puzzle piece when bringing a design vision to life, however achieving the unique and one-off result can be a real journey in of itself.
Below we will walk through the general process, limitations and considerations around using milled reclaimed hardwood timber in an architectural design.
Sourcing Reclaimed Hardwood
The first step in using beautiful rustic hardwoods is to first find them!
This process involves sourcing the hardwood beams from historic structures like bridges, wharfs, warehouses and old telephone poles to name only a few. These timbers are often made from dense, durable hardwoods like Jarrah, Ironbark, Kauri, or Rimu among many others, all which have withstood the test of time and the natural elements during their tenure in-situ.
The beams are extracted from their original settings, ensuring minimal damage to the timber. This process requires skilled labour and specialized equipment to handle the sheer size and weight of these beams and can be more about logistical manoeuvres than anything else.
Storage and Processing
Once the beams are sourced, they are transported to the Interlink storage and processing facility in Christchurch where they are cleaned and tidied. This involves removing any ex-industry steel like nails, bolts, plates and chains, as well as other contaminant that may be embedded in the wood such as stones, shellfish and sand. The beams are then pressure washed to remove dirt, grime, and any remaining debris. This cleaning process is crucial. It allows for thorough assessment of suitability for milling and prepares the wood for cutting to ensure machinery and blades are looked after. As you can imagine, a big 40mm wide band-saw blade will not withstand any foreign contaminant very well!
Milling the Beams
Milling reclaimed hardwood presents several unique challenges that require careful consideration and specific machinery and tools. One of the primary difficulties lies in the density of seasoned timber. Over time, hardwood becomes incredibly dense, making it tough to cut through with standard saw blades. This density requires specific hardwood blades; however, they still suffer from significant wear and tear necessitating frequent sharpening or replacement. Additionally, the heart of the timber, which is the innermost part of the wood, can be of varied softer density which can be problematic to cutting straight, consistent solid timbers
It is paramount the timber is cut with skill and expertise so the effects of log-wane, which is the outside curvature on the timber log does not eat into the finished dimensions, and to ensure inherent cracks within the reclaimed timbers hold solid in the finished milled piece. While also noting some log-wane and cracks are okay, and to be expected โ adding to the authentic character of re-purposed hardwood.
For precision pieces (usually smaller), running the timber through a bandsaw, a thicknesser or large planer can be required to achieve consistent and precise thickness and flatness. A real juggling act when machinery is often limited with the size of timber it can process at certain dimensions, so multiple passes through a band-saw, or use of multiple saw types may be required.
Avoiding any hand processing or using hand tools is the focus, but this is not always the case when crafting a unique piece of quality reclaimed timber.
The above steps ensure that the reclaimed wood is not only cut to the correct dimensions but also prepared for its final application, whether it be decorative, structural or functional. Not only having the timber at the specified size, but also the surface and texture is another aspect to factor in ahead of time, as once the piece is to size, additional processes like sand-blasting, accelerated antiquating, and wire brushing can then be applied in a methodical manner.
Remember, you can cut off, but you cannot add back on, so having plenty of lead-time for consultation, sourcing, milling, processing and delivery will always ensure the timbers are crafted correctly first time, with less stress and more aesthetic magic!
Connecting Sourcing with End-User Applications
To bridge the gap between the journey of sourcing and end-user applications, it’s important to understand the processes required to work with reclaimed timber. This will assist with everyoneโs understanding and align expectations, so we are all on the same page.
Here are some key insights:
- Adaption and finetuning: Everything about reclaimed timber, even after milling tends to be โapproximateโ. Using big saws on big timbers that are unique in form and condition means things like dimensions and colouring are never exact. Those designing and installing will be aware of the minor adaptions and changes often required when on site. Small trims, sanding, chiselling and planing are often required to get a good proper fit, and this can only be done during the installation process.
- Moisture Content: Reclaimed timber often has a higher moisture content which can affect its stability. It’s essential to properly dry the wood before using it in construction or furniture making, or to understand the limitations around size, fixings and timing of installation.
A fully seasoned (dried) hardwood can be very challenging to modify and adapt onsite, and equally, an unseasoned hardwood will distort as it dries. Kiln drying is usually not possible, due to the typically large dimensions, so, finding the ideal balance (and time!) between the two seasoned states for functional installation can be key. - Fading: Often the final faded visual finish is achieved after installation, once in place for a summer/winter and shouldering months, where distortions like warps and bows can be mitigated with prompt installation and fitting, so the timber is nestled in its forever home while it re-seasons. Manual Fading is possible, talk to us more about this on first communication.
- Insect Damage: While reclaimed wood is generally durable and tough to penetrate, it may have been exposed to insects over the years. Inspecting the wood for any signs of insect damage is crucial should a totally flat surface be sought. Alternatively, the likes of Seaworm holes can add awesome character to pieces once milled back and can be a real asset to the โreclaimed stateโ. This is where the thorough assessment after the cleaning but before the milling occurs is critical, but sometimes the presence of insect damage is not known until the cutting is underway.
- Variability: Each piece of reclaimed wood is unique, with its own set of characteristics such as knots, grain patterns, colour variations, and even timber species. This variability can be both a challenge and an opportunity, allowing for truly one-of-a-kind creations. One should expect some differences between a set of beams, even if they are of the same timber species, and sourced from the same salvage location. Once all in place however, variations can bring a whole set of timbers together and really makes a visual point of difference compared to newly manufactured timbers.
- Environmental Impact: Using reclaimed wood is an environmentally friendly choice, as it reduces the demand for new manufactured timber (often chemically treated with little-no character) and helping to preserve forest stocks. It also slows the demand of newly manmade materials which are very resource intensive to make and offers very little natural appeal and history. It’s a sustainable option that aligns with the growing trend towards eco-conscious living, which we should all be aware of by now.
Conclusion
The journey of transforming reclaimed bridge and wharf beams, telephone poles, and other large timbers into custom-sized architectural elements is a testament to the beauty and versatility of hardwood. From sourcing and processing to milling and installation, each step requires skill, experience, adaptability, and a deep appreciation for the material. The end result is a range of stunning, unique pieces that add character, a story, and sustainability to any project. It can be a time-consuming process but when methodically planned and soundly communicated the milestones fall in place as they should. Milling reclaimed timbers can be an exercise in flexibility with our artistic design visions but using a natural material that will last for many decades carries great reward that is not easily compromised.
Whether you’re a designer, homeowner, or architect, working with reclaimed hardwood offers endless possibilities and a chance to create something truly special.
