From Forest to Foyer

Photos courtesy of Patrick Russell | All American Floor Sanding and Installation

Patrick Russell of All American Floor Sanding and Installation, based in Ocala, Florida, recently undertook a remarkable project that showcased the uniqueness of heartpine. Set in a newly built home, the project used pine harvested directly from the property on which the home stood. The wood, with its dense grain and tight patterns, presented a one-of-a-kind opportunity for Russell to create a floor that was as personal as it was stunning.

ā€œThe homeowners had all this wood stacked up ā€“ 5,000 square feet of it ā€“ and they wanted to use it for their new home,ā€ recalls Russell. ā€œHeartpine is our specialty, but with its tight grain and the sap content, it is just a different kind of wood. That said, itā€™s my favorite to work with.ā€

Unfortunately, working with wood that Russell didnā€™t procure himself came with its challenges. The heartpine had been milled roughly and required significant and unforeseen preparation before installation.

ā€œWhen I first saw the wood, I realized it was only roughly milled. Nothing was perfect at all,ā€ Russell explains. ā€œWe had to go through it all, chop it, cut out the bad parts, and re-groove everything. It was a lot of work, but it was necessary to ensure the floor would turn out beautifully.ā€

As the project progressed, the homeowners expressed their desire to incorporate large live edge slabs they had stored in their carport into the floor design. This idea led to the creation of a stunning basket weave pattern bordered by these live edge slabs.

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ā€œI had envisioned a basket weave pattern already because itā€™s one of my favorite floors,ā€ says Russell. ā€œThere were no blueprints for what we were about to do, but we just went with it.ā€

The installation process was a collaborative effort, with friends and colleagues lending a hand. Dave Marzalek of DM Hardwood Designs helped with the hand-scraping of the floors downstairs, which was necessary due to the sap content in the wood.

ā€œWe tried to sand everything, but we knew we would not be able to get a foot downstairs without clogging the paper. It was just so sappy,ā€ recalls Russell. ā€œWe could sand the upstairs flat, but everything downstairs had to be hand-scraped.ā€

The foyer, measuring around 250 square feet, became the projectā€™s focal point. The intricate basket weave pattern was laid out carefully, with a starburst design in the center square and matching starburst patterns in each corner.

ā€œThe very center square is actually a starburst pattern, and all of the corners were done this way too,ā€ notes Russell. ā€œThe project also included the incorporation of crosses made from olive wood from Bethlehem. These crosses were embedded into the floor, adding a personal and meaningful touch to the design.ā€

The installation process was not without its challenges, particularly when it came to fitting the soldier boards to the live edge slabs. Russell credits Justin Boone of Boone Flooring for helping to mill and saw pieces of the pattern, ensuring that everything fit together seamlessly. ā€œWe had to fit the soldier boards to the live edge slabs using a router,ā€ explains Russell. ā€œIt was a lot of work, but the result was worth it.ā€

The final steps included hand-scraping everything and applying a clear epoxy to the voids in the live edge slabs.

ā€œWe sealed the floor using Zinsser, followed by two coats of Loba Hybrid with Amberizer, which had some tint added,ā€ says Russell. ā€œWe waited a day, buffed it up, and hand-rubbed several areas. We then top-coated it with Loba Duo.ā€

Russell also credits Pat Hodges, who assisted in finishing the scraping and laying the final touches. The entire foyer took about a week to complete, but the result was a breathtaking floor that the homeowners were thrilled with.

ā€œEvery morning we worked, the homeowners would come in drinking their coffee, and you could feel the amazement,ā€ reflects Russell. ā€œThis wood was so special to them as it had come off their property. They had been stockpiling it for years before the house had even been built. They were so great to work with and so happy with our work. Everyone that comes in the house cannot believe it.ā€

Russell advises others facing a similar project to inspect the material carefully before beginning.

ā€œWhen I walked in, I was walking in on someone elseā€™s job, meaning I was not the one who had ordered this wood,ā€ he says. ā€œIf you donā€™t know what mill it came from, you need to look it over before you agree to a price. We didnā€™t find many issues until we initially attempted installing it.ā€

He also emphasizes the importance of ensuring that the tongue and groove pieces fit together correctly, especially when dealing with wood of different widths. In the end, the project was a success in terms of the craftsmanship and the personal connection the homeowners felt to their floor.

ā€œThey were so happy with our work,ā€ Russell says. ā€œAnd that made all the hard work worth it.ā€

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