From workshop to hotel suite

A full interior fit-out — where every piece of furniture, every panel and every fixture is bespoke — is one of the most complex deliveries in the joinery trade. For hotel suites, luxury villas and high-end commercial spaces, we follow a seven-stage process that has been refined over hundreds of projects across Portugal, France and the Caribbean. Each stage has clear deliverables, approval gates and quality checkpoints. Here is how it works.

1. Site Survey with Laser Measurement

Every project begins with a physical site survey. We use Leica laser distance meters and Faro 3D scanning equipment to capture precise room dimensions, wall deviations, floor levels and ceiling profiles. In renovation projects — Haussmannian apartments, historic chalets, colonial villas — walls are rarely plumb and floors are rarely level. A laser survey captures these irregularities to sub-millimetre accuracy. The survey data feeds directly into our CAD system, eliminating the measurement errors that cause costly on-site modifications. For international projects where a physical visit is not immediately possible, we provide the architect with a detailed survey protocol and checklist so their local team can capture the data we need.

2. CAD Design and Architect Review

Our technical design team produces full 3D models and manufacturing drawings in SolidWorks and AutoCAD. Every piece is drawn at 1:1 scale with complete hardware specifications, material call-outs and finish codes. We share these drawings with the architect or interior designer for review, typically over two to three rounds of revision. This stage resolves all dimensional conflicts, confirms material selections and locks in the hardware schedule. Nothing goes to the workshop floor until the architect signs off on the final drawing set.

3. Material Procurement

Once drawings are approved, we issue purchase orders for timber, sheet materials, veneers, hardware, glass, stone and any specialty components. We maintain stock relationships with European hardwood suppliers and specify by board grade — FAS (First and Seconds) for visible faces, with lower grades acceptable for concealed structural elements. Veneers are selected for grain match and colour consistency across the full project. For large hotel fit-outs, we procure a single batch of veneer to ensure continuity across all rooms. Lead times for material procurement range from two to six weeks depending on species and availability.

4. CNC Machining and Hand Finishing

Production begins with CNC cutting and shaping on our Biesse and Homag machining centres. CNC ensures repeatable accuracy to within 0.1mm across hundreds of identical components — critical for hotel projects where every room must match. After machining, components move to hand-finishing stations for edge profiling, sanding through progressive grits (120 to 320), and detail work that machines cannot replicate. Curved elements, inlays and decorative mouldings are hand-shaped by our craftsmen. Lacquering is performed in our dust-controlled spray booth with two-component polyurethane systems, sanded between coats.

5. Pre-Assembly and Quality Control

Before any piece leaves the workshop, it is fully assembled on our QC floor. Doors are hung, drawers are tested, hardware is adjusted, and every surface is inspected under raking light for finish defects. We photograph the assembled piece from multiple angles and record all dimensions. This pre-assembly step catches issues that would otherwise surface on site — where corrections are ten times more expensive and cause programme delays. Only after QC approval is the piece disassembled for packing.

6. Container Shipping

Disassembled components are vacuum-wrapped, edge-protected with foam profiles and secured in custom timber cradles inside standard shipping containers. We use 20-foot containers for residential projects and 40-foot containers for hotel fit-outs. Each container is loaded according to an installation-sequence plan: the pieces needed first on site are loaded last. Containers ship from Lisbon or Leixoes to destinations worldwide, with transit times of 5 to 7 days for European ports and 14 to 18 days for the Caribbean. We handle all customs documentation and import permits.

7. Installation by Our Own Team

This is the stage that sets our process apart. We do not subcontract installation. Our own installation teams — the same craftsmen who work in the Portugal workshop — travel to site for every project. They understand how each piece was built because they built it. A typical hotel suite installation takes three to four days per room. A full villa fit-out ranges from one to three weeks depending on scope. Our team carries a complete tool set and a stock of touch-up materials for any minor site adjustments. The project is not complete until the architect conducts a final walk-through and signs the acceptance certificate.

Timelines

For a standard project, the full cycle from survey to installation runs 10 to 16 weeks. Complex projects with extensive custom hardware or rare materials may extend to 20 weeks. We provide a detailed programme at contract stage with milestone dates for each of the seven stages, giving architects full visibility over the delivery timeline.