About This Project

Ali Stephens of Pallet Furniture, spent a very long time dismantling and denailing pallets in preparation for the floor and an equally long time securing all the slats in place. The underlying framework was made from the 2×4 you are left with after deconstructing a pallet, carefully arranged and filled with Leca ball insulation. The underlying floor was painted with a special rust proof paint called Red Oxide before the laying of the pallet floor.

Over 180 kilograms of Leca ball insulation was used underneath the pallet floor.

Leca is a special type of clay that has been pelletised and fired in a rotary kiln at a very high temperature. As it is fired, the organic compounds in the clay burn off forcing the pellets to expand and become honeycombed inside and smooth on the outside. The ceramic pellets are lightweight, free draining, insulating and have a high crushing resistance. Leca is chemically neutral and does not contain any environmentally harmful constituents and can be recycled and used again.

The finished floor in all it’s glory! Next is the sanding and oiling of the floor once all the interior of Gaia is built.


Say hello and come aboard.