In this blog post, we'll be sharing the story of a unique project that almost slipped away but turned into a remarkable accomplishment. It all started when a customer approached us with a request to install an accent wall in his newly constructed home. Little did we know that this project would push us to think creatively and overcome various challenges. Join us as we take you through the journey of turning a customer's vision into reality.
1. Exploring the Feasibility:
When the customer first approached us, we realized that his idea of using epoxy for an accent wall was not a common practice. He explained that he wanted a seamless and distinctive look, different from traditional natural stone options. To ensure the success of the project, we estimated that it would require four layers of specialized epoxy. Given that the wall was intended for a fireplace, we emphasized the importance of selecting a product with high heat and UV tolerance. To better understand the project's requirements, we agreed to meet the customer at the job site.
2. Assessing the Challenges:
Upon meeting the customer, we took measurements and discovered that the wall section was 6 feet wide by 20 feet tall. This raised concerns about the weight and the method of securing a 180-square-foot wooden panel to the wall. Further examination of the job site revealed that building the piece offline and transporting it would be impractical due to entryway and ceiling constraints. We suggested building it on-site, but creating a dust-free environment seemed nearly impossible. Additionally, we couldn't guarantee the long-term durability of the piece without knowing how securely it would remain attached to the wall. With a commitment to quality and longevity, we made the difficult decision to turn down the job.
3. A Second Chance:
Weeks later, the customer reached out again, persistently asking us to reconsider. He even had the homebuilder call us to express admiration for our decision to prioritize quality over financial gain. Intrigued by their persistence, we decided to explore alternative solutions. After careful thought and preparation, we discovered that the fireplace in the home was purely for aesthetics. This realization opened up new possibilities for reducing the weight and creating a dust-free environment.
4. Overcoming Challenges:
To reduce the weight, we decided to construct the piece out of Foam Board, a lightweight material. We also found a solution for mounting a large television by inlaying 2 by 12 boards into the wall. To create a dust-free environment, we purchased and built a plastic room, reminiscent of those seen in science fiction movies.
5. Bringing the Vision to Life:
With the challenges addressed, we contacted the homeowner and agreed to take on the job. We began by templating the area where the piece would be secured to the wall and proceeded to build it on-site. Using 1/2 inch MDF strips, we created a rounded edge and carefully routed the edges on both the top and bottom. After filling the joints with a joint filler, we applied the first layer of epoxy. To ensure durability during the lifting process, we inlaid fiber mesh with epoxy using 1/2 inch foam board. Several coats of a black base epoxy were applied, and once dry, we added the design. Finally, a clear coat was applied to protect the piece from potential damage.
6. The Final Result:
With the help of a 20-foot-tall scaffolding, a team of eight personnel, and five gallons of specialized silicone, we secured the piece to the wall. The homeowner was thrilled with the final product and wrote us a fantastic review. He even referred us to several of his neighbors, showcasing the success of the project and our commitment to delivering exceptional results.
Conclusion:
This project taught us the importance of perseverance and thinking outside the box. By overcoming challenges and finding innovative solutions, we were able to turn a seemingly impossible task into a remarkable accomplishment. We take pride in delivering quality and longevity to our customers, and this project will always hold a special place in our memories.
