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From the tree trunk to the finished floor

At Mardegan Legno we follow each phase of manufacture because we want to guarantee maximum quality: from felling the trees to drying the boards, to the artisanal treatment of the surfaces.

The 10 phases of the process

I - Choosing the wood

We buy logs through an auction system. We only choose trees that come from European forests managed and protected respecting rigorous environmental, social and economic standards.

II - Sawing the logs

We personally follow the production process from the beginning. First of all, the outer layer of the log is removed, then it is sawn to obtain the thin wood boards known as lamellas.

III - Preparing the lamellas

Lamellas of different sizes are obtained from the sawing process and subsequently dried in kilns fuelled by the wood waste produced by the sawing. Once out of the kiln, the lamellas receive an initial surface treatment.

IV- Selecting the lamellas

This is the delicate process of visual selection, when it is decided what each lamella will be used for. Once they arrive at the storage facility, the lamellas are sorted by the Mardegan Legno experts according to their appearance, size and the selection they belong to (Selection A, B, Mixed).

V - Collecting the lamellas

When the customer sends in an order, the number of lamellas required to cover the specified number of square metres is collected from the storage facility.

VI - Assembly

The layers are assembled by hand, the lamellas are glued using non-toxic vinyl glue.
The hot press guarantees the stability of the floor. Once assembly is completed, the next step is cutting and profiling the boards.

VII - Phases of surface processing

The boards are now ready to receive the treatments requested in the order. Of the 12 phases of manufacture, 9 are done by hand by the master artisans who work for Mardegan Legno.
The boards are worked on one by one, and can be sanded, planed, sandblasted, rounded and textured. Each process is a set of unique gestures fuelled by passion and experience.

VIII - Colouring

Mardegan Legno has always stood out for its large catalogue of colours.
What makes this characteristic exceptional is the fact that the processes involved are carried out by hand using brush techniques, spray techniques and, in many cases, rag painting.

IX - Finishing

The finishing treatment can be of two kinds, both of which avoid the use of formaldehyde, and other toxic or harmful substances.The first type is water-based painting followed by UV curing, which is particularly appreciated for its easy maintenance and high resistance to dirt and wear.The second type is an oil-wax treatment, ideal for nourishing the wood and enhancing its natural effect.

X - Packaging

The boards have reached the end of the production process.Each order is carefully packed by hand in packages that can hold 4-8 boards, with a spongy layer to protect the finishes.Each pallet is custom-made to protect the boards during transportation.Each consignment includes a packing list which describes the content, useful both for an immediate check of the contents and to assist the fitter when laying the flooring.

Surface treatments

We put all of our artisanal expertise into our flooring, to bring to light the most intimate face of the rich wood material. Planed by hand, brushed, sawn, Mardegan Legno's floors are unique because they are the result of natural materials and artisanal work.

 

  • Brushed

    A series of brushes removes a minimal portion of the softest part of the surface, highlighting the cathedral figures. All 4 sides are chamfered.
    COVENT GARDEN
  • Presanded

    Mechanical sanding to achieve an especially smooth surface. All 4 sides are chamfered.

  • Sawn

    An antique woodsawing process is recreated on the 7.2 mm thick lamelle. The blade leaves its marks on the surface, which are then hand-sanded. All 4 sides are chamfered.

  • Planed and weathered

    This is the most complex manual process, combining a planing technique with a weathering process which recreates an older style and the signs of the passage of time. All 4 sides are chamfered.

  • Weathered

    Hand-sanding creates a “valleyed” effect along the board and its edges. This highlights the three-dimensional quality of the surface giving it a timeworn quality. All 4 sides are chamfered to be rounded and irregular.

  • Hand-planed

    Expert artisans plane each individual board by hand, using a traditional plane. The surface comes to life and imparts a play of volumes and movement to the floor.
    All 4 sides are chamfered.

  • Smooth planed and sandblasted

    Very delicate planing employed only on very large boards that are then enriched and enhanced by sandblasting.
    All 4 sides are chamfered.

    COVENT GARDEN
  • Sandblasted

    A process which uses extremely high pressure to remove the softest part of the fibre, creating a surface with a timeworn appearance.
    All 4 sides are chamfered.

    COVENT GARDEN
  • Hand-sculpted

    An exclusive manual process carried out by Mardegan Legno’s master artisans using chisel planes. The final result is an evocative interweaving of inlay work and the cathedral pattern on the individual boards.
    All 4 sides are chamfered.

  • Sawn and sandblasted

    The 7.2 mm lamelle are sandblasted as well. The grain and figures highlighted on the board combine with the marks left by sawing to create the exclusive Mardegan Legno geometrical pattern. All 4 sides are chamfered.

    COVENT GARDEN
  • Rounded and hand-planed

    In addition to hand-planing, the longer sides of the boards are rounded to give the floor a satisfying wave-like effect.

  • Rounded and sandblasted

    The wave effect on the longer side of the boards gives a three-dimensional effect to the surface, while the sandblasting highlights the natural wood grain and figures.

    COVENT GARDEN

Colouring and surface protection

The colours of the surfaces are the result of Giuseppe Mardegan's meticulous research. Our master artisans apply these colours by hand to render each nuance unique, the artist's trademark, something that cannot be achieved with a machine.

How a Mardegan Legno colour comes into being

At Mardegan Legno we offer a wide range of colours, in 119 tonalities. The nuances are achieved by manually applying the various shades to the individual surfaces. Our experts carry out all phases of the process by hand, using spray, brush and ragging techniques. We know that choosing to handcraft each colour renders each surface unique and irreplaceable. For this reason, each floor has its own distinctive traits. Incisions, treatments and colours: each surface will be unique. This is our distinctive trait, the value we believe in and that we want others to recognise and appreciate.

Surface protection

Feeling free to walk barefoot on your own floor: that is the emotion that inspires the creation of every Mardegan Legno floor. In line with our philosophy, we have chosen to use non-toxic treatments, that respect the wood and those who will live in contact with it.

Painting with UV-cured water-based colours

This is a protective treatment which uses only water-based colours that preserve unaltered the resistance, characteristics and colour of the floor.
It is utilised in all our collections except “Harmony&Nature” and “Antichi Sapori”.

Oil-wax treatment

This treatment is carried out manually by our master artisans by applying various coats of a special mixture of oil and hard wax. This is an emulsion that nourishes the floor and makes it partially water-repellent, a protective treatment that needs to be repeated periodically.
The oil-wax product is applied to the “Antichi Sapori”, “Harmony&Nature” and, upon request, “Natural Wood” collections.

Floors and walls

In our workshops we bring the beauty of wood back to the surface. All our surfaces have two things in common: an attentive research process and finishes applied rigorously by hand.

Request information

Please feel free contact us for any doubts or queries you may have about Mardegan Legno surfaces.