When Jim Graf got the call to create a custom inlay 31 feet in diameter as well as thousands of feet of custom parquet for the Sacred Heart University Guest House in Fairfield, Conn., he did not hesitate. Having worked on high-profile projects in his career spanning from the Ronald Reagan Presidential Library to the platform for George H.W. Bush’s inauguration, he was accustomed to tackling unusual and demanding work.
The project began with detailed scaling in CAD, creating a framework for the design to be created using red oak and walnut. Then, “Using a CNC machine, I cut the components for the first 7 feet of the medallion. Beyond that, every piece had to be crafted by hand on a table saw with custom jigs and slides,” Graf says. “Countless adjustments were made along the way to ensure each part was dimensioned with absolute precision.”
Once each piece was cut, it was added to the pre-assembly of the medallion in the shop to confirm a seamless fit. The pre-assembly covered 32 tables measuring 4 by 8 feet. Each piece was connected with tongues, grooves or splines, with 0.010 of an inch left between them to allow for expansion during the transition from production to installation. This process took about two months to complete. Once assembled in the shop, the installers from South Windsor, Conn.-based Dalene Flooring were invited so they could see exactly where spacing was required.
Once finalized, each piece—there were 2,054 in all—was tagged with a unique code, creating a precise system for reassembly. The medallion was then divided into five crates for shipping.
Upon arrival at Sacred Heart University, the inlay was reconstructed exactly as intended—much like assembling an intricate, enormous puzzle. “The installation itself was efficient—what had taken me roughly 400 hours to build was installed in about 40 hours,” Graf says. “I only received one call at the start of the process regarding spacing, and as far as I know, no additional cutting or sanding was needed on site,” Graf says.
Once installation of the medallion and the Fontainebleau parquet was complete, the Dalene Flooring crew sanded and finished all 5,072 square feet with waterborne finish, creating a welcoming space for Sacred Heart guests for decades to come.
SUPPLIERS: Distributor: UCX | Flooring contractor: Dalene Flooring | Wood flooring: Graf Custom Hardwood | Finish: Bona US
Watch a video showing the creation of this floor:
