​Project Information:

 

• Location: Monticello, Napa, CA

• Description: Floor slab honing - New construction

• Architects: Edmond&Lee, San Francisco, CA

• General contractor: Devlin McNally Construction, San Francisco, CA

• Concrete Contractor: Partners Contracting Inc, San Rafael, CA

• Floor Diamond Machining Contractor: DelGrosso Design, Santa Rosa, CA

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Specifications:

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• Slab placement: Floor topping slabs poured with custom concrete mix, large size aggregate hand-embedded during placement.

• Grinding and surface prep: the top 1/4" to 3/4" top layer of the slab was removed by grinding to expose the large aggregate. Equipment: Superabrasive Lavina 30 equipped with metal bond diamond buttons.

• Grouting & filler: large cavities exposed by grinding pop-outs were filled in excess with a custom mixture of Metzger McGuire SRG polyurea, sand aggragate, medium size aggragte and grinding dust, and later ground flush.

• Honing: Blue Star transitional ceramic diamond tooling

• Cracks and dents repair: Metzger McGuire SRG polyurea

• Densifier: Ameripolish HS Hybrid Lithium Silicates

• sliding doors thresholds: custom mix of CTS Rapidset TRU PC and medium size aggregate.

• Sliding doors tracks inlays: Custom mix of Metzger McGuire SRG (multiple colors mix), fine and medium stone aggregate.

• Sealer: Ameripolish X Link E WL

• Wear coat: Prosoco Polish Guard

 

Notes. This incredibly unique project took a year and a half in planning and mock ups, and nine months in the making! Like the rest of the building, from architectural design to materials choice, from finishes to landscaping elements, this project is a unique masterpiece and to date the most demanding project we ever worked on. The incredible amount of details and custom specifications necessary for this built required team work that involved every contractor on the job.

The most unique feature of this hydronic heat floor slab is the use of large stone aggregate, embedded by hand into the topping slab during placement, and later resulting in its unique look.

Because of the extensive amount of grinding needed to expose the large aggregate, voids formed by pop-outs and stone breakage had to be filled and rebuilt using the most advanced techniques and products. Needles to say, very few companies nation wide have the necessary talent, experience and knowledge to produce such incredible results. We are one of the few! The outdoor concrete was finished with the same process as the indoor slab, creating a seamless design, but with a slightly lower final grit in order to provide the needed additional slip resistance proper for pool decks and patios.

We are very proud of being part of this project, and being able to produce such a unique, artistic and technologically advanced floor.