The renovation of the Duval County Court House, a municipal facility in Jacksonville, was one of the largest and highest profile construction projects in north Florida in recent history, valued at approximately $35 million.

Completed in May 2012, the seven-story, approximately 800,000 sq. ft. structure has a façade made of pre-cast concrete and glass, and it houses 51 criminal and civil courtrooms, judges’ chambers, offices and meeting rooms. In addition to the large scope of the project, the renovation presented Moyer Marble and Tile, with a multitude of challenges —including a variety of different surface materials for the 300,000 sq. ft. interior space, substrate limitations and major time constraints.

“Custom Building Products consistently provides us with exceptional technical support and quality systems that perform above and beyond our expectations. This project was a perfect example of why we partner with Custom for our projects”, said Rich Santos, Commercial Project Manager, Moyer Marble and Tile Company.

A team effort overcame some major pre-installation challenges.

“The project was a challenge from the start,” explained Jeff Stone, Territory Manager, Custom Building Products. “There was an eagerness to get the project completed quickly but we faced significant challenges with the substrate.” Like many large projects, the floors had been treated with a curing compound/sealer, which would not allow for proper water absorption —essential for proper bonding to the surface of the substrate.

Based upon an initial inspection, Moyer Marble and Tile and Custom Building Products determined that the floor needed to be mechanically abraded (bead blasted) for a successful installation. “The concrete slab had a burnished steel trowel finish, with a cure and seal that provided a high psi impervious surface that was not rough or porous enough for the setting material to adhere to it,” said Santos.

“Despite these initial challenges, the ceramic and stone tile installation was a success — a testament to the integrated designed approach of everyone involved,” said Nick Macrino, Architectural Consultant, Custom Building Products. The project drew on Custom’s diverse expertise and resources throughout the southeast region — everything from architectural and technical consulting to sales and distribution.

Custom products met the project’s demands and exceeded everyone’s expectations.

Large format tiles, mostly glazed porcelain with some stone decos, were installed in all interior areas (walls, floors, bathrooms, entrance and hallways, etc.) with the exception of the courtrooms. ProLite® Tile and Stone Mortar from Custom Building Products was selected for the installation, due to its non-sag, non-shrink properties that prevent lippage on the floors. ProLite was also used to tile the corridor walls, which were the length of three football fields.

Other products that were key to the installation included RedGard® Waterproofing and Crack Prevention Membrane, CEG-LiteTM 100% Solids Commercial Epoxy Grout. RedGard was chosen because it provides a continuous waterproofing barrier with outstanding adhesion and reduces crack transmission. CEG-Lite was selected for the grout joints because it helps to ensure non-sagging in the walls and non-slumping on the floors.

A true team effort.

“In addition to using quality products, Moyer Marble and Tile brought professionalism and a level of experience that made it all look easy, despite the challenges of a project of this size and scope” said Stone. Their experience doing quality installations for three generations really paid off and is evident when you see the level of quality in their work up close.”

“The Custom team was great to work with,” said Santos. “Their technical support was always there when we needed it — and they delivered high quality products that were right for the job at a competitive cost. The key to it all was great communication. They’re responsive and they care.”