Precast terrazzo island
Sometimes we are asked to do things that seem nearly impossible. In this case, the architect envisioned a massive 3″ thick terrazzo island that looked like it was cut from a massive block.
Casting 3.5″ thick terrazzo slabs
The Stone Design team created simple molds and cast oversized slabs that were to be milled to 3″ finished thickness. Epoxy re-bar and carbon fibre re-enforcement was utilized, but held back from the edges to allow for mitre cuts.
Once the slabs were de-molded, they were delivered to Matrix Marble to be machined to 3″ with the terrazzo exposed. Stone Design then brought the milled pieces back to our shop to polish and finish.
Mitres cut and delivered to site.
Once the slabs were delivered to SSC Countertops, they were milled to finished dimensions. Mitres were cut for all returns and waterfall edges. This type of milling needs to be extremely accurate to ensure a tight joint.
Installation of the island
Once the massive terrazzo island pieces were delivered, the install could begin. Alignment was super key as the return waterfall edges needed to land directly on the brass divider strip on the terrazzo floor installed the previous year.
With such a challenging piece, nothing can be rushed. Everything needs to be planned, test fit, trimmed, fit again and finally set when perfect. This time lapse shows how patience is of the upmost when undertaking such a unique installation.
Monolithic – no joints
Although mitres were cut into the returns, the design intent was to have the island appear seamless. Stone Design chiselled out the mitred edge, glued in pieces of limestone and back poured more terrazzo to ensure a seamless appearance. The overall effect leaves the appearance of a monolithic piece of terrazzo protruding from the floor.
Backpour the corners
Once the mitres are chipped out, they are crudely formed with tape and back poured. When cured they are ground, polished and sealed.
Finished pictures will be coming soon. As soon as we complete project, they are covered up immediately so other work can continue. Stay tuned for updates.