When I received this project in mid-last year, to be honest, my first reaction was not excitement, but nervousness. At a banquet hall in a coastal city’s Intercontinental Hotel, with an area of 780㎡, the design style is modern luxury + ocean elements. The requirements are that the carpet must support multiple scenarios such as banquets, conferences, and weddings, and also be scrutinized by senior executives and media during the opening celebration—only 52 days for construction, from sampling to installation.

Final delivery result: completed 2 days ahead of schedule, passed inspection on the first attempt, and the project director of the client wrote four words on the acceptance form—”Exceeds Expectations”.

Today, I will break down the entire project process—not to show off, but to let peers and clients see: a high-quality hotel carpet project delivery involves many more steps behind the scenes than most people imagine.

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1. Project Background: Why we dared to take this order

First, clarify the project’s hard metrics:

Project Parameters	Requirements
Project Positioning	Five-star Intercontinental brand, opening celebration venue
Area Size	Main banquet hall 780㎡ + pre-function hall 260㎡ = 1040㎡
Design Style	Modern luxury + ocean ripple elements
Process Requirements	Handmade gun-stitching (custom pattern)
Material Requirements	80% New Zealand wool + 20% nylon 66 blended yarn
Flame Retardant Grade	GB 8624 B1 level
Project Duration Requirements	52 days (including sampling, production, logistics, and paving)
Delivery Standards	Seamless splicing, one-time acceptance

Completing a 1040㎡ custom handcrafted gun刺 carpet project in 52 days, while the industry standard schedule is 70-80 days. Why are we confident to take on this project?

Because we have a trump card: the factory base in the Pearl River Delta has always maintained flexible scheduling for sampling and production lines, plus our core gun刺 team of 36 members is fully staffed, ensuring capacity. We also clearly communicated to the client — 52 days is possible, but design modifications during the sampling phase need to be limited to within 2 rounds; exceeding 2 rounds would be insufficient.

There is a very honest saying about the project: the premise of making a promise is that you are thoroughly familiar with your factory. From yarn procurement, dyeing and preparation, backing fabric inventory to master scheduling, every detail has been coordinated with the production side before order acceptance.

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Section Two: From Design Draft to Sampling: The Most Painful 17 Days

In the original plan provided by the designer, the main pattern of the banquet hall features three different shades of blue waves interlaced, forming a gradient from light to dark from the entrance to the stage. It sounds simple, but after receiving the drawings, three issues were found:

1️⃣ The three shades of blue plus the gradient transition require11 color layers, each layer needing independent stitching.

2️⃣ The overlapping edges of the waves are not straight lines but irregular curves, requiring the master to judge transition points on-site during gun刺.

3️⃣ The 780㎡ plan needs to be divided into6 sections, with pattern matching accuracy controlled within ±1mm.

Two rounds of sampling were conducted during the sampling phase. The first round of sampling revealed that the ”step-like” effect in the gradient transition area was too obvious — two adjacent color shades showed visible color band boundaries to the naked eye. The process team’s solution was to introduce a ”middle transition color” yarn in the transition area, changing the original two-color boundary into a three-color blended transition. This adjustment increased the number of color layers from 11 to 14, but the smoothness of the transition was visibly improved to a perceptible level.

The second round of sampling was very satisfactory to Party A, who signed directly to confirm. From receiving the drawings to final approval,took 17 days, which is 2 days longer than the planned 15 days, but the subsequent production process caught up.

💡 Tips: For customized pattern projects, it is recommended to arrange the sampling process to be completed at the factory, not in the showroom. The lighting in the showroom and the actual lighting in the banquet hall (usually a mix of large-area LED and natural light) are completely different, and the same color may appear 3-5 shades cooler or warmer under different lighting conditions.

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3. Production process: 36 people, 27 days, 1040㎡

After sampling confirmation, mass production begins. This is the most intense phase of the entire project.

Process key points:

• Needle刺 density:50 stitches per square foot(Standard five-star hotel hand-stitched刺 usually ranges from 40-45 stitches; this project requires higher precision for gradient patterns, so it has been increased.)
• Yarn combination: New Zealand wool and nylon 66 in80:20 ratioPre-mixed and then刺 applied to ensure a handcrafted texture while improving wear resistance
• Flame retardant scheme: Cotton backing adoptsdouble-sided flame retardant spray + flame retardant latex coatingThe SGS test report shows that the critical heat radiation flux reaches7.2 kW/m², far exceeding the B1 level threshold of 4.5 kW/m²

36刺刺师傅 divided into 6 groups, each responsible for one piece (each piece approximately 130-170㎡). After each piece is completed, the quality inspection team will performTripartite Joint Inspection: The pile height deviation is controlled within ±0.5mm, the pattern splicing edge marking error does not exceed ±1mm, and the backing coating thickness uniformity meets the standard value of 95%.

There is an easily overlooked detail when doing manual gun刺 projects:The temperature and humidity control for each piece during production. Yarns have different elasticity and elongation rates under different humidity conditions. If six pieces of carpets are completed under different humidity conditions, there may be size inconsistencies after final installation. Our approach is to keep the workshop temperature and humidity constant during production atTemperature 22±2℃, Humidity 55±5%, ensuring each piece is completed in the same environment.

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Section Four, Logistics and Installation: Often underestimated risk links

Carpet production is only part of the work, completing 70%. The remaining 30% involves logistics and installation.

The finished handmade gun刺 carpet area of 1040㎡ weighs approximately3.2 tons, divided into 6 rolls for transportation. Each roll is about 4 meters wide, with lengths ranging from 30 to 50 meters. The two main concerns during transportation are:Moisture and compression deformation。

The packaging plan is: each roll of carpet is first wrapped withwaterproof breathable membrane, then protected with bubble wrap, and finally sealed with a woven bag. Moisture-proof packs are placed at both ends of each roll. During loading, the rolls are placed vertically and must not be stacked.

For installation, our own installation team from Yisen was dispatched to the site, consisting of 4 people, who used3 daysto complete all installation and edging. During the installation process, a现场问题 was encountered—the maximum levelness deviation of the banquet hall floor was5mm, although within the tolerance range for carpet installation, it will affect the foot feel and visual flatness. Our installation team used self-leveling repair mortar to locally level areas with deviations exceeding 3mm, which took half a day longer but ensured the final velvet surface was completely flat.

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V. Post-Delivery: Customer Feedback and Project Review

On the acceptance day, more than ten people from the client side came — including the owner’s representative, hotel engineering director, design team representative, and the Intercontinental Group regional operations director. They walked back and forth on the carpet several times, squatted down to feel the seams, and used a strong flashlight to side-light and check the uniformity of the velvet surface.

Acceptance conclusion:Passed on the first attempt, no corrections needed.

The project director later said a few words at the project review meeting that left a deep impression on me: ”The three concerns I had before—color deviation, visible seams, uneven suede—none of them occurred. Your delivery standards are among the top tier even within the Intercontinental system.”

Project follow-up (after 6 months): At the beginning of this year, we conducted a routine follow-up. The hotel has hosted more than 40 banquets and conference events. The banquet hall manager reported that it has been cleaned three times (dry foam cleaning), and the suede surface remains in good condition, with no issues such as pilling, fuzzing, or color differences.

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Six, Review: What this project has taught us

After completing each project, an internal review is conducted. This project is especially worth documenting:

Things done correctly:

• Production capacity pre-scheduling has been reserved.Elasticity of 15%In actual production, the issue of exceeding the sample approval deadline by 2 days was addressed.
• Persisted through the sample stage.Two wheelsThere was no skipping of the second confirmation to meet the deadline.
• The onsite problem anticipation ability of the paving team—proactively addressed the ground levelness issue without waiting for the client to notice.

Can do better:

• An additional waterproof protective layer can be added to the packaging solution. During logistics, it encountered rainy weather, and although no damage occurred, greater caution should be exercised.
• There was friction between the early project phase and the design team regarding color language consistency. Next time, it is recommended to hold a ”Color Expectation Alignment Meeting” before sampling, where the design renderings and actual yarn color swatches are compared under the same light source.

The most valuable gain for us is: It has been proven that Yisen Carpet has a complete delivery capability in the field of high-end custom handmade gun刺, from design collaboration, sample confirmation, large-scale production to on-site installation. Controlling the entire chain is what truly convinces customers to make a purchase.

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If you need to learn more about the execution details of this project, or want to see specific sample comparison images and on-site installation records, you can directly contact Yisen Carpet's project team. Every project we do is archived—not as a version for clients to view, but as a real record for our own review.