One of the many benefits of real wood floors is that new flooring can be made to look like old wood that already exists in a home. However, that doesn’t mean it is always easy to do. DJ Townsend of I.R.B. Flooring in Pico Rivera, California, was up for the challenge on a recent job.
“This project was to match a 20-year-old hardwood floor so seamlessly that new and old would feel like one,” recalls Townsend. “A contractor reached out knowing the level of precision required hadn’t been achieved yet. After walking the jobsite, I knew it was possible, but it would take time, patience, and craftsmanship.”
Featuring 5” rift and quartersawn white oak with planks ranging from 8’ to 14’, Townsend began the project by creating custom stain samples until a perfect match was made. The wood was delivered and left to acclimate inside the home. Throughout a two week timeframe, he stopped by the house regularly to check and document moisture levels to make sure everything was stable before installation.
In the process of covering about 1,300 square feet, Townsend says preparation was everything. “The concrete slab was ground down, leveled where needed, sealed, and topped
with ¾” plywood, which was glued and nailed for maximum stability,” he explains. “In high risk moisture areas like the kitchen and entryways, we applied Bostik Roll- Cote for added protection. From there, it was all about control. Locking in the first two rows, maintaining lines, and building in washer rows every 5’ to 7’ to allow the floor to move naturally.”
The flooring was installed at a 45-degree angle using a nail down method with glue assist, which Townsend notes is a more demanding approach than standard installs. The craftsmanship is what he believes truly defined this floor.
“Every single board was handbeveled before it ever touched the ground. Once installed, we sanded the entire floor and then handscraped it individually, plank by plank,” shares Townsend. “This wasn’t just hand scraping. It was pushing the technique further than usual.”
Townsend intentionally created deeper, more pronounced textures, cutting between 1/8” and ¼” into the surface across long, continuous sections. Nothing was done short or random. He says controlled, intentional movement gave the floor its own bold and custom identity.
Another potential obstacle to work around was the layout of the home. “There were five detailed wraps, including a 20’ kitchen island, two pillars, and perimeter borders which had to flow seamlessly with a starting run of nearly 50’. Every line mattered. Every angle had to be exact,” recalls Townsend.
Throughout the project, Townsend notes that he used Bona dustless systems, Bona adhesives and finish, DuraSeal stains, Bostik Roll-Cote for moisture protection, white oak flooring from Galleher, and Lockwood dyes. He adds that having help from his colleagues, as well as Omar Ascencio with Lionheart Flooring out of Riverside, California, made a big difference onsite.
He shares this advice, “When you have the right people involved, everything runs smoother, more efficiently, and successfully.”
Townsend says the client loved how things turned out. “At the very end, the homeowners asked for just a bit more depth in the color,” he notes. “We adjusted by tinting the finish slightly darker using a Lockwood dye and that final step pulled everything together beautifully. The result was exactly what we set out to achieve.”
A true example of the details that Townsend says can only be achieved with years of experience, problem solving, and dedication to the craft, all defining highlevel hardwood flooring.
