Value Engineering

In 2018-2019, Albany International Airport management was gearing up for major improvements. The base bid for flooring to replace carpet was for an ultra-thin manufactured terrazzo-style tile, seen as a budget-friendly option. However, before plans were finalized, the way was opened for a conversation about a poured-in-place thin-set epoxy terrazzo as an alternative to the bid.

Those weighing in on the terrazzo side included the architect, Michael W. LaMontagne, AIA, Principal Architect at C&S Companies in Syracuse, NY. Through multiple conversations, he recounted that airport representatives’ fears, based on several misconceptions about their options, were laid to rest.

Airport management thought there’d be more issues with terrazzo than with tiles, that the joints in the tiles would allow for more movement, while terrazzo would crack. They believed they would have more control and better color options with manufactured tile. They also thought it would be easier to phase the project with the tiles and keep the airport active during construction. “We had a lot of work to do,” Mr. Montagne recounted.

One disadvantage of manufactured terrazzo-style tiles is the unavoidable joints. The seamless finish of poured-in-place terrazzo is far easier to maintain.

An example in point was seen at another New York State airport. While the rest of the floor was poured-in-place terrazzo, a white ultra-thin 2×2-foot format terrazzo-style tile was used in one terminal to save money.

Mr. Blackburn was called in later to check the floor and try to help them out of their predicament. He reported high foot traffic, and expansion and contraction, caused the grout joints to open up and turn dark. Cleaning machines only managed to pick up the dirt from the joints and spread it around.

“They can’t get it clean because it’s not monolithic,” Mr. Blackburn explained. “They deeply regret it.”

Seamless Advantage

Ultra-thin tiles installed with abutted joints lead to other problems, he continued. Cleaning chemicals seeping in leads to delamination and staining. Topcoats have to be stripped and reapplied.

“There’s nothing worse, especially with lighter color ultra-thin because of the grout joint problem,” Mr. Blackburn declared. “It’s the only floor product I speak out against this way. It offers no actual savings and is so clearly an inferior product.”

As is standard for an epoxy installation, Albany’s terrazzo included proper treatment of the substrate control joints and a full crack-suppression membrane. NTMA standard maintenance for poured-in-place terrazzo is inexpensive and simple, using an auto scrubber or mop and bucket.

Walk a Job

If you are looking for a product that is new on the market and may resemble poured-in-place terrazzo, “walk a few jobs,” advised Joe Iorio, Project Manager at Yorie Tile & Terrazzo of Allentown, PA, the terrazzo contractor at Albany. You can see how a product has worn over time and whether it will meet your expectations.

By careful phasing of the installation, Albany International continued operations during the terrazzo installation, as is standard in similar instances.

At Albany, the choice was clear: a lower bid number, shorter lead times, and quicker install. The result? A seamless, simple-to-maintain product that will equal the life cycle of the building.