At Plankbridge, we take immense pride in every aspect of our craftsmanship, and the painting department is no exception. Here, we go behind the scenes in the paint shop with our seasoned paint specialists Tim and Abbi, who talk us through the process from prep work to the finished hut…
Can you walk us through the painting process?
Tim: It all starts with the prep. We start by sanding the surfaces of each piece, ensuring it’s smooth and the best surface for the paint. It can take hours to get right but, for me, it’s the most satisfying part – getting it perfect before moving on to the spray shop. We are fortunate to have two purpose-built facilities on site for that: one is big enough to take the whole hut, where the interior walls and the exterior cladding are painted; the other spray shop is where the smaller items are painted – the furniture and sometimes the doors and windows. The chassis, meanwhile, are powder-coated down the road in Blandford, where the metal work is blasted, etch-primed, powder-coated and then baked in big ovens.
What wood do you work with?
Abbi: Our furniture is from furniture-grade Poplar wood, which is perfect for painting, and the internal walls are clad in tongue-and-groove Scandinavian red wood, carefully graded to be largely knot-free. We have it machined to our own specification so that it finishes at 19mm thick, which adds to the thermal and acoustic properties within the hut.
What’s the best part of your job?
Tim: Definitely seeing the transformation from raw wood to the finished article. When we get everything prepped and ready, applying the paint is the easy part. I specialise in spray painting, which ensures a consistent, even coat every time. The technique gives a professional finish, and after nearly 30 years of doing this, I can pretty much say I’ve perfected it!
What are the biggest challenges you face in your role?
Abbi: Managing drying times is one of the biggest challenges. During winter, the cold slows the drying process down, and in summer, a heatwave can cause the paint to dry too quickly. Thankfully, we have special heating systems that ensure that everything dries properly and evenly.
Have you had any unusual painting requests?
Abbi: We’ve had some really fun and creative requests over the years. One that stands out was a project where we painted two huts for Skanes Djurpark ‘Shaun the Sheep Land’ in Sweden. We used 30 different shades of paint for that, each with its own colour scheme!
Favourite colours over the years?
Abbi: We once painted a hut in dark grey for one customer and it had the feel of a bachelor pad, which was stunning. I also loved the vibrant pink we painted one of the Aller Dorset kitchens.
How do you ensure the paintwork is durable?
Tim: We use high-quality, sustainable paints that are designed to withstand the elements. Durability is really important, especially for the exterior of the huts, which are exposed to all kinds of weather throughout the year. The level of wear and tear internally depends on the way the hut is used but, with the proper care, it will stay looking great for years to come.
