Custom Eco-Friendly Engineered Floor Made from Reclaimed Bleacher Boards

Here at Pioneer Millworks we have a menu of more than 50 standard products. But we continue to push the envelope and work with clients who come to us with their own unique vision. In fact, nearly half of all the jobs we do each year are custom. We love these partnerships into uncharted waters and all the challenges that they entail. The extra sweat and tears spent in the production of these orders often leaves us feeling especially proud of the end results.

One recent custom order of which passed through nearly every hand in our shop was 8,000 square feet of Eco-Friendly Engineered Floor made from Reclaimed Douglas Fir Bleachers. Destined for a large corporate headquarters in California, here is what was involved:

  1. Bleachers were sourced from across the nation, from Webster, New York to Portland, Oregon and numerous stops in-between. Because only solid Douglas Fir bleachers could be used for this order, our acquisitions team traveled across the country to find the perfect stock. This was something of a treasure hunt as most bleachers that were installed in the last 50 years are plastic, pine or laminates. Bleacher - 0
    reclaimed bleacher board art pioneer millworks

    Some of the gum and graffiti we found on our collection of boards.

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    2.After the bleachers were cut to 8′ lengths (the length of the plywood), we fully surfaced each board in our moulder and put them in our kiln for several days. This brought all the wood to a consistent moisture content and killed any nasty fungus that might have resided after decades of sweaty gym shorts leaving their mark (we learned this the hard way).Bleacher - 3Bleacher - 4Bleacher - 5

  2. The holes left from the original carriage bolts which once secured the bleachers to a metal frame, are drilled out and filled with custom plugs. Our detail oriented crew did an exceptional job matching the grain of the plugs to the grain of each board. Bleacher - 6Bleacher - 7Bleacher - 8Bleacher - 9Bleacher - 10Bleacher - 11
  3. Once plugged, each board was again surfaced in the moulder and then run through our frame saw. Here, a series of blades sawed each board into three thin wear layers.
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    Going in.

    Coming out.

    Coming out.

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  4. On our glue line, each wear layer was carefully adhered to a FSC Baltic Birch plywood substrate. Bleacher - 15Bleacher - 16Bleacher - 17
  5. Finally, these glued-up boards were run through the moulder a third and final time where the tongue and groove was milled. After defecting out any remaining irregularities, each board was end-matched and stacked to ship. Bleacher - 18Bleacher - 19Bleacher - 20Bleacher - 21Bleacher - 22Bleacher - 23Bleacher - 24

I think that it is safe to say that everyone involved in the project is especially proud of this beautiful one of a kind floor. Keep the custom projects coming!

 

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Reclaimed Gym Flooring and Bleachers Puts Eco-Minded School Design Firm Ahead of the Class

Original gym flooring with reclaimed bleacher boards add character to the Ashley McGraw office in Syracuse, NY.

Original gym flooring with reclaimed bleacher boards add character to the Ashley McGraw office in Syracuse, NY.

We teamed up with a local architectural and interior design firm in Syracuse, NY  to make their workspace a little more playful for employees. Ashley McGraw Architects collaborated with us to bring reclaimed gym flooring and bleacher boards into their snazzy, newly remodeled office space.

The material was sourced from Geneva Middle School, just 55 miles from Ashley McGraw and 28 miles from our headquarters in Farmington, NY. “Sourcing this so close to our headquarters, from a gym I played sports in, was remarkable,” shares Jered, one of our reclaimed wood experts. “When Ashley McGraw reached out looking for reclaimed wood for their office remodel, I knew immediately that we had the right product. It is a great fit and it feels good when a local company gives reclaimed wood a second life.”

The gym flooring was reclaimed by Pioneer Millworks from Geneva Middle School in Geneva, NY.

Tony de-nails the gym flooring on-site as we reclaimed it from Geneva Middle School in Geneva, NY. While the planks are checked again at our mill, this initial de-nailing made packaging and shipping much more efficient.

Our friends at Ashley McGraw specialize in school design and were excited to bring iconic school building materials into their space. (They cherish their memories of sometimes winning a game of dodgeball and finding an okay square dancing partner.) The office remodel utilized Geneva Middle School bleachers and gym flooring. Original surfaces were maintained allowing the mixture of court lines and varying school-spirited colors to be celebrated. “It looks like confetti!” said Susan Angarano, Interior Designer with the firm. Tonal differences in the wood from the various schools helped create a border from the circulation spaces into the office areas at the company. Bleacher boards (sans bubble gum) were incorporated as screen walls and ceiling accents.

We salvaged the hard maple flooring and Douglas fir bleachers from the 1920s gymnasium during the building’s deconstruction last spring. As always, special attention was given to maintaining the original appearance of the wood, including surface finishes, bolt-holes, colors, and milling.

Reclaimed from educational institutions across the country, gym flooring can be re-installed as is, with the color schemes creating a random and playful reminder of its source.

Reclaimed from educational institutions across the country, gym flooring can be re-installed as is, with the color schemes creating a random and playful reminder of its source.

“Gym flooring is one of our most colorful reclaimed products with a history most folks quickly relate to,” says Jered. The painted planks from the gymnasium were sorted from the others and used in the circulation spaces of the office, while the remainder of flooring from two other schools was used in the materials library. The old gym flooring has varying lengths, some up to five feet long while the bleachers boards are up to sixteen feet long.

Reclaimed oak boards were used for wall cladding in the break room.

Reclaimed oak boards were used for wall cladding in the break room.

We’ve certainly found likeness in our commitment to sustainability and conserving the world’s resources. “Every day, we challenge ourselves to embrace the possibility of a fully sustainable world,” states Ashley McGraw. “Our contribution is schools and campuses that respect, support, and nurture the learning experience and work in concert with the earth and its resources.”

David Ashley and Ed McGraw founded Ashley McGraw Architects in Syracuse in 1981. Their work includes classrooms, laboratories, recreational, and residential buildings, as well as sustainability strategies and master plans for public and private primary, intermediate, secondary, and high education facilities.

Reclaimed oak boards were used for wall cladding in the entry way.

Reclaimed oak boards were used for wall cladding in the entry way.

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A tour of reclaimed Chestnut Hill

Jered took a recent trip to Boston and stopped at Chestnut Hill mall to check out our reclaimed wood in its new home. Here’s what he found:

When you walk up to Anthropologie, you’re greeted by doors made of a mixture of Douglas fir and Cypress milled from wood reclaimed from wine vats. That same wood accents select areas of the store as flooring. Our sister company, NEWwoodworks, created a shelving unit made of reclaimed American Gothic Oak.

Anthropologie entrance with wine vat stock siding.

Anthropologie entrance with wine vat stock siding.

 

NWW AG Oak shelves

Anthropologie American Gothic Oak shelving.

Fir Cypress flooring

Anthropologie wine vat stock flooring.

Anthropologie wine vat stock flooring.

Anthropologie wine vat stock flooring.

Madewell features Character Select Heart Pine flooring that has no finishing on it, though some is painted white as part of their more recent designs.

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Character Select Heart Pine at Madewell.

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Character Select Heart Pine at Madewell.

Next up is Eileen Fisher, where the ladies working there told Jered they get lots of love for the floor. The flooring is Engineered American Gothic Elm which has been stained and refinished on site.

AG Elm

American Gothic Elm flooring.

The new Basset Store features FSC Certified Red Oak siding that has been heavily brushed and primed in our shop then finished in the field.

FSC Red Oak

FSC Certified Red Oak siding at Basset.

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FSC Certified Red Oak siding at Basset.

We’re excited to see our ‘old’ wood getting new life in Boston. Jered had a good time visiting (he said something about the best cannolis in the country?!) and is already gearing up to go back in late Fall. We’ll be sure to share more!

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What’s new in The Big Apple

Jered has been trekking to NYC quite often over the past few months and has snapped many pictures of our wood in use. Flooring, paneling, and siding are most common but there are new twists including patterns, shapes, and finishes.

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We’re so inspired by this blasted Foundry Maple wall at WeWork on Broadway.

 

At Pop at Pod restaurant in Manhattan, you’ll find sanded reclaimed gymnasium flooring from a high school in Minnesota, and rough-sawn FSC Certified Western Red Cedar ceiling t&g.

At Pop at Pod restaurant in Manhattan, you’ll find sanded reclaimed gymnasium flooring from a high school in Minnesota, and rough-sawn FSC Certified Western Red Cedar ceiling t&g.

Chop't Creative Salad Company in Brookfield Place features a creative use of reclaimed Settlers' Plank Oak in a herringbone pattern.

Chop’t Creative Salad Company in Brookfield Place features a creative use of reclaimed Settlers’ Plank Oak in a herringbone pattern.

 

Jered stopped in at Blue Ribbon Fried Chicken, off of East Houston, and spotted a nice vertical grain reclaimed Heart Pine counter crafted by our sister company NEWwoodworks. (He also said the chicken is absolutely amazing!)

Jered stopped in at Blue Ribbon Fried Chicken, off of East Houston, and spotted a nice vertical grain reclaimed Heart Pine counter crafted by our sister company NEWwoodworks. (He also said the chicken is absolutely amazing!)

Timberland's corporate showroom in NYC incorporated American Gothic reclaimed oak flooring and paneling, as well as reclaimed white pine ceiling joists salvaged from a sawmill in New Hampshire.

Timberland’s corporate showroom in NYC incorporated American Gothic reclaimed oak flooring and paneling, as well as reclaimed white pine ceiling joists salvaged from a sawmill in New Hampshire.

 

Heart Pine on the facade of this Brooklyn pasta restaurant warmly welcomes its guests. Beveled edges define the planks and add texture while the character complements the clean horizontal lines.

Heart Pine on the facade of this Brooklyn pasta restaurant warmly welcomes its guests. Beveled edges define the planks and add texture while the character complements the clean horizontal lines.

 

We shipped out some industrial salvaged wood for wall cladding to the very first Wolverine company store, located in in Nolita. The old planks were split in half and wire-brushed, giving the look of an industrial stacked wall. The client, contractor, and patrons are thrilled with the finished appearance and we have to agree - it turned out pretty darn cool.

We shipped out some industrial salvaged wood for wall cladding to the very first Wolverine company store, located in in Nolita. The old planks were split in half and wire-brushed, giving the look of an industrial stacked wall. The client, contractor, and patrons are thrilled with the finished appearance and we have to agree – it turned out pretty darn cool.

 

The overlapping and alternating corners of the reclaimed Ash planks add visual interest to the wall, cabinets, and cashier wrap at Charlie Bird restaurant in SoHo.

The overlapping and alternating corners of the reclaimed Ash planks add visual interest to the wall, cabinets, and cashier wrap at Charlie Bird restaurant in SoHo.

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