How Americo Ricky Migliore Minimizes Tile Waste on Large Projects

Introduction

Minimizing tile waste on large-scale installations requires more than just experience—it demands precision, planning, and a deep understanding of the materials involved. Americo Ricky Migliore, a renowned tile and stone installation expert based in New York, has mastered the art of maximizing tile usage while reducing unnecessary waste. His techniques are a result of decades spent managing commercial and high-end residential projects across the New York tri-state area. This article

dives into how Americo approaches large projects, ensures efficiency, and keeps sustainability in focus through waste reduction.

Planning the Layout Before Any Tile Is Cut

Before Americo ever lays a tile, he invests significant time into planning. The importance of pre-layout cannot be overstated, especially in large projects where even small miscalculations can result in substantial waste. He carefully evaluates the space, measures it multiple times, and uses digital floor plan software to simulate layouts.

For Americo, tile layout planning is not just about aesthetics—it’s a logistical strategy. He considers the dimensions of each room, transition points, thresholds, and the direction of natural light.

This allows him to optimize where cuts will fall so that partial tiles aren’t wasted. Often, Americo will shift the starting point of a layout slightly to ensure that both ends of a corridor or wall have near-full tile pieces, which eliminates the need to discard thin, awkward cuts.

By establishing a clear strategy from the start, Americo ensures that cuts are predictable, symmetrical, and minimal. He also factors in material-specific constraints, like grain direction in natural stone or pattern orientation in decorative tiles, all of which can impact how much waste a project produces.

Ordering the Right Amount of Tile – Not More, Not Less

Ordering tile isn’t as straightforward as multiplying square footage by a buffer percentage. Americo understands that different tile materials, shapes, and patterns influence waste rates. For example, herringbone or diagonal patterns inherently require more cuts than a straight lay, which increases the likelihood of waste.

Americo calculates tile quantities based on:

Layout complexity

Tile size and format

Number of transitions between rooms

Anticipated cuts due to obstacles like columns or fixtures

Instead of using a generic 10–15% overage rule, he creates tailored estimates based on project variables. This helps avoid the trap of over-ordering tiles “just in case,” which leads to material stockpiles and budget bloat. At the same time, under-ordering can be worse, especially if tile batches run out and new batches don't match in color or texture.

Americo often requests a combination of full boxes and loose tiles from suppliers when feasible. This allows him to order precisely what’s needed without being forced to overstock, particularly on rare or expensive tile types.

Reusing Offcuts Strategically

One of Americo’s most effective techniques for minimizing tile waste is repurposing offcuts. In many projects, installers discard pieces that are too small or oddly shaped to be reused. Americo, however, identifies where these fragments can still add value—such as behind appliances, under cabinetry, or around fixtures.

For example, a piece that was cut from one corner of a room may fit perfectly in another corner that mirrors its shape. On one luxury bathroom project, Americo reused offcut marble tiles to create an accent border around the bathtub platform. This not only saved material but elevated the design by introducing visual contrast.

He also trains his crew to think creatively and keep offcuts organized during installation. By stacking them by size and shape as the project progresses, Americo ensures that these leftover tiles remain accessible and usable rather than being lost in debris piles.

Beyond aesthetics, strategic reuse of offcuts helps reduce disposal costs, lowers environmental impact, and keeps the workflow efficient—especially important when working in commercial high-rises with limited waste-handling capacity.

Using Specialized Tools to Improve Cut Accuracy

Americo invests in high-precision cutting tools, waterjet machines, and advanced scoring devices. These tools are crucial in producing clean, accurate cuts, especially on high-end materials like porcelain slabs and natural stone. More accurate cuts mean fewer broken tiles and a better chance of using nearly every piece in a box.

In his New York operations, Americo also uses digital tile saws with measurement presets that reduce human error. These saws can be set to repeatedly cut tiles of the same size, ensuring consistency and reducing the likelihood of unusable mistakes. The ability to execute precise cuts not only saves tiles but also enhances the overall look and feel of the finished installation.

Furthermore, Americo keeps multiple blade types on hand to match the tool to the material. Using the wrong blade on a delicate tile can chip or break it, rendering it useless. With the right combination of technique and tooling, he greatly reduces the chance of breakage.

Training Crews on Material Handling and On-Site Efficiency

While Americo brings leadership to every project, he attributes much of his success in waste reduction to how well-trained his crews are. He has developed specific protocols for how tiles should be transported, handled, stored, and cut on-site.

For instance, boxes of tiles are not opened and spread out on uneven surfaces, where they might crack. Instead, tiles are stored on padded, level surfaces close to the work area to minimize movement. He also emphasizes acclimating tiles to room temperature before installation, particularly in winter, to prevent sudden temperature-induced cracking.

Americo runs tile orientation meetings before major installations, where he walks his team through the layout plan, expected challenges, and areas where offcuts can be reused. This shared understanding ensures that everyone, from junior installers to foremen, contributes to the goal of minimizing waste.

Additionally, he introduces on-site mockups for intricate designs. These dry runs help catch potential issues in layout or cuts before adhesive ever hits the tile, saving time, material, and frustration.

A New York Mindset: Practicality Meets Precision

Being based in New York, where square footage is expensive and project timelines are tight, Americo Migliore has developed a mindset rooted in practicality without compromising the elegance of his designs. His projects—ranging from corporate headquarters to boutique hotels and custom residences—often take place in environments where every tile counts.

Americo views tile waste not just as a cost issue but as a quality issue. Excessive waste can indicate poor planning, rushed work, or lack of coordination. Through his thorough approach, he reinforces professionalism and craftsmanship at every stage of the project.

What sets Americo apart is how he aligns environmental responsibility with luxury construction. Reducing waste isn't just about cutting costs—it's about respecting materials, honoring the design intent, and delivering long-lasting installations that require minimal repair or replacement.

Conclusion

Minimizing tile waste on large projects is an art and science that Americo Ricky Migliore has refined through years of dedication and expertise in the tile and stone installation field. From strategic planning and precise cutting to smart crew training and material management, Americo’s methods ensure that each tile is used to its fullest potential. Operating out of New York, he blends craftsmanship with efficiency in a way that exemplifies best practices in modern construction. Through his work, Americo not only saves materials but also sets a standard for excellence that others in the industry strive to match.