For those who are not completely familiar with the manufacturing of floors, knowledge of certain facts, industry standards, and characteristics should be helpful for the homeowner, builder and even the installer when considering custom flooring.

Custom floors are floors that are made up in specifically requested, thickness, width, length, and species. These floors can be requested either, solid or engineered, prefinished or unfinished. They can have added texture such as original saw marks, wire brushing, or hand-scraped. They may be made from antique wood, new domestic wood, tropical woods, and other specialty woods.

The beauty of custom floors is that they are unique, one-of-a-kind products that can be the focal point to many decors, and a product particularly pleasing to the customer. Often custom floors are made to blend in with a particular architectural plan.

Custom floors as a rule take longer to produce and may have unexpected delays, particularly if the boards are very wide and long. Wide width (> 5”), Long length (>4’), end-matching and whether it is engineered or prefinished, may require that the manufacturing process occur at more than one mill. When more than one mill is involved delays can be lengthy. Most floors that are produced for “on the shelf” sales, have been produced so many times in such large volumes, that most questionable flaws, unusual character and wastage have been eliminated. However, these flooring products are limited in width, length, sometimes thickness, and species. There are two advantages to “on-the-shelf” products. They are readily available and usually less expensive than custom floors. These products are usually limited in width, length, and species.

Wastage Factor May Be Greater Than Industry Standards With Custom Floors. – Across the board in industry standards, a 10% wastage factor is allowed for all floors. This allows for undetermined required flooring board cuts in each structure. This wastage factor may be larger with custom floors, particularly with longer, wider floor boards and certain, more unstable species, such as specialty woods and antique woods with excessive character. Also, the installer has a big affect on the percentage of wastage. Some installers have a large wastage factor for speed or personal likes or dislikes.

The manufacturer must determine the wastage factor but the customer needs to be familiar with the specie’s character so they are not surprised by excess wastage and unexpected character noted in the wood. Since every customer is different in likes and dislikes, the manufacturer cannot easily determine this fact from customer to customer.

Most manufacturers are willing to replace any un-useable boards prior to installation. However, once the flooring product has been delivered, accepted, and left on the job site for any length of time, the manufacturer can no longer be responsible for the condition of the product or missing quantities. It is important that the wood be inspected and counted at the time of delivery. If the product at that time is not the quantity, or product ordered, both the shipping company and the manufacturer must be notified before the product is left on the job.

In the case of custom engineered floors, there may at times be “pops” to occur in the installed flooring. Two things may cause this. One is the lack of glue in some areas, due to the installation process and the other is release of the veneer in some areas. There are kits available and well know processes for correcting these problems, which are both lasting and visually aesthetic. Industry standards allow for up to 25% of the flooring to delaminate before it is considered a replaceable floor.

If the installer is not confident in the product, the manufacturer should be called in to correct the flooring before the flooring is altered, removed or destroyed.

Usually, the customer, builder, supervisor and installer can go to inspect the product being used to make the flooring as well as see the manufacturing process. This helps to eliminate disappointment in the final product.

Remember that wood is a beautiful and forgiving natural product with both flaws and character and it can react to the environment. It can be altered in transporting and during the installation process. The manufacturer cannot be held responsible for these alterations or missing products, once they are on the job site.

Once the custom flooring is initiated and money expended for materials, any requested changes results in extra expenses and therefore extra charges. Custom floors are neither refundable nor returnable and if the customer requests replacement of useable boards due to color or character, there will also be an adjusted price for sorting and possible grade increase.

E. D. Woods Lumber Co. is always willing to discuss the product and process and help educate the customer in order to have a satisfied customer and a quality product.